Service Manual

RV Generator Set

HDKCA (Spec A−D)

HDKCB (Spec A−D)
HDKCC (Spec A−D)
HDKCD (Spec A−D)

English − Original Instructions 10−2010 981−0540 (Issue 14)

 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

diesel warnings
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

i
SECTION PAGE

Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Maintaining the Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
4. PREPARATIONS FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing / Installing Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Disassembling / Reassembling Housing and Mounting System . . . . . . . . . . . . . 4-4
5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Thermostat and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9. ENGINE AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
High-Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
10. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Generator Winding Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Generator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

ii
SECTION PAGE

Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

11. CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Control Board (Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Local and Remote Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Line Circuit Breakers CB1, CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Relays K1, K2, K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Voltage Sense Transformer TX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Troubleshooting With Table 12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13. BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
CONTROL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
AC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

iii
THIS PAGE LEFT INTENTIONALLY BLANK
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL S Let the engine cool down before removing the
before operating the genset. Safe operation and coolant pressure cap or opening the coolant
top performance can only be obtained when drain. Hot coolant under pressure can spray
equipment is operated and maintained proper- out and cause severe burns.
ly.
S Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
Only trained and experienced service person- gear stowed in the compartment can restrict
nel with knowledge of fuels, electricity and ma- cooling air.
chinery hazards shall removed, dismantle and
dispose of the generator set. See Service man- S Make sure all fasteners are secure and
aul. torqued properly.
S Do not work on the genset when mentally or
Some generator set installation procedures physically fatigued or after consuming alcohol
present hazards that can result in severe per- or drugs.
sonnel injury or death. Only trained and experi-
enced personnel with knowledge of fuels, elec- S Used engine oil has been identified by some
tricity and machinery hazards should perform U. S. state and federal agencies as causing
generator set installation procedures. cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
The following symbols in this manual alert you to S Ethylene glycol, used as engine antifreeze, is
potential hazards to the operator, service person toxic to humans and animals. Clean up spills
and equipment. and dispose of used engine coolant in accor-
dance with local environmental regulations.
DANGER Used to alert you to a lethal hazard
S Keep multi-purpose fire extinguishers handy.
which you must take steps to prevent severe Multi−purpose fire extinguishes are used for
personal injury or death, as when you are in the fires that involve ordinary combustible materi-
vicinity of High Voltage equipment. als such as wood and cloth; combustible and
flammable liquid fuel and gaseous fuels; live
WARNING Used to alert you to a hazard or un- electrical equipment (North America or US: ref.
safe practice that can result in severe personal NFPA No. 10)
injury or death.
S Genset installation and operation must comply
with all applicable local, state and federal
CAUTION Used to alert you to a hazard or un-
codes and regulations.
safe practice that can result in personal injury
or equipment damage. S Generator sets with a sound shield shall not be
run with the service doors remove/missing.
Electricity, fuel, exhaust, moving parts and batter- S Engine components can be hot and cause se-
ies present hazards which can result in severe per- vere burns. Hot coolant under pressure can
sonal injury or death. spray and cause severe burns.

GENERAL PRECAUTIONS S Use personal protective equipment when per-

forming periodic maintenance operations such
S Keep children away from the generator set. as gloves, safety glasses, etc.
S Do not use evaporative starting fluids. They
THE HAZARD OF CARBON MONOXIDE
are highly explosive.
S To prevent accidental or remote starting while WARNING Engine−driven generators can pro-
working on the genset, disconnect the nega- duce harmful level of carbon monoxide that can
tive (−) battery cable at the battery. injure or kill you.

v
ONLY YOU CAN PROTECT YOURSELF ing device before storing the vehicle or parking
FROM CO POISONING! it in a garage or other confined space.

S Watch constantly for people near the exhaust S The exhaust system must be installed in accor-
of the generator set while it is running. dance with the genset Installation Manual.

S Make sure exhaust cannot enter the living S Engine cooling air must not be used for heating
quarters through a window, vent or door. working or living spaces or compartments.

S Make sure all CO detectors or audible alarms DIESEL FUEL IS COMBUSTIBLE

are working properly.
S Do not smoke or turn electrical switches ON or
S Pay attention to the signs of CO poisoning. OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
S Check the exhaust system for corrosion, ob- ment. Keep flames, sparks, pilot lights, arc-
struction and leaks each time you start the producing equipment and all other sources of
generator set and every eight hours if you run ignition well away.
it continuously.
S Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
GENERATOR VOLTAGE IS DEADLY
S Disable the automatic genset starting feature GASOLINE IS FLAMMABLE AND
of an inverter-charger or other automatic start- EXPLOSIVE
ing device before servicing the genset.
S Because this generator set is an Ignition Pro-
S Generator electrical output connections must tected device, no substitutes are permitted for
be made by a trained and experienced electri- the parts listed in the Critical Parts Index of the
cian in accordance with applicable codes. generator set Parts Catalog. They must be
purchased from Onan and be installed in ac-
S The genset must not be connected to the pub- cordance with the generator set Service Manu-
lic utility or any other source of electrical power. al by those who are trained and experienced in
Back-feed could lead to electrocution of utility marine generator set service.
personnel and damage to equipment. An ap-
proved switching device must be used to pre- BATTERY GAS IS EXPLOSIVE
vent interconnections.
S Wear splash−proof safety glasses.
S Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth- S Do not smoke or permit flames or sparks to oc-
ing and shoes are dry, stand on a dry wooden cur near the battery at any time.
platform or rubber insulating mat and use tools S To reduce arcing when disconnecting or recon-
with insulated handles. necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
ENGINE EXHAUST IS DEADLY it last.
S Inspect for exhaust leaks at every startup and MOVING PARTS CAN CAUSE SEVERE
after every eight hours of running.
PERSONAL INJURY OR DEATH
S Learn the symptoms of carbon monoxide poi- S Disable the automatic genset starting feature
soning in the Operator’s Manual. of an inverter-charger or other automatic start-
S Never sleep in the vehicle while the genset is ing device before servicing the genset.
running unless the vehicle is equipped with a S Do not wear loose clothing or jewelry near
working carbon monoxide detector. moving parts such as PTO shafts, fans, belts
S Do not operate the genset when the vehicle is and pulleys.
in a confined space, such as a garage. S Keep hands away from moving parts.
S Disable the automatic genset starting feature S Keep guards in place over fans, belts, pulleys,
of an inverter-charger or other automatic start- and other moving parts.

vL
 FLAMMABLE VAPOR CAN CAUSE A Avoid strong oxidizing agents − incompatible with
DIESEL ENGINE TO OVERSPEED sulfuric acid, nitric acid, caustics and aliphatic
amines.
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in PROTECTIVE MEASURES
possible fire, explosion, severe personal injury and
Refrain from eating, drinking or smoking when us-
death. Do not operate a diesel-powered genset ing the product. Adopt a high standard of personal
where a flammable vapor environment can be
hygiene. In case of skin contact, wash immediately
created by fuel spill, leak, etc. The owners and
with soap and water.
operators of the genset are solely responsible for
operating the genset safely. Ensure good ventilation and avoid heat sources.
Avoid breathing mist, if there is a risk of vapour, or
SUBSTANCE HAZARDOUS TO HEALTH particulate, use a suitable organic vapour mask.

Generator sets use substances, and emit and Eye protection, gloves, overalls, impervious apron
create wastes that can cause health risks. Genera- should be used. Avoid contamination inside the
tor set operators must use appropriate personal gloves. If overalls become contaminated, discon-
protective equipment (such as clothing, gloves, tinue use and clean thoroughly.
protective glasses/goggles, and respiration equip-
ment) when exposed to fuel, oil, coolant, wet batter- STORAGE/TRANSPORT
ies, grease, cleaning agents, or other substances
Store and transport only in correctly marked con-
exposed to lung, eyes, or skin. Use appropriate
tainers. Keep containers closed when not in use.
containers for transport, storage, and disposal of
Keep cool, out of sunlight, away for naked flames
waste substances. Follow local regulations for dis-
and strong acids, do not freeze. Store well away
posal and recycling.
from food−stuffs and drinking water. Take special
care to avoid discharge into drains, sewers and wa-
ANTIFREEZE (FLEETGUARD − ES ter−courses.
COMPLEAT/EG PREMIX)
Contain leak/spill with sand, earth or non−combus-
This antifreeze is also know as an ethylene glycol tible, absorbent material to prevent entry of sub-
based coolant; summer coolant; coolant additive. It stance into drainage/sewerage system, water−
is purple coloured, viscous liquid, with a mild chemi- courses and land. Eliminate all ignition sources,
cal odour, is soluble in water and harmful. It con- use plastic shovel to transfer to suitable container
tains ethylene glycol, and diethylene glycol. Ethyl- and dispose of unwanted or absorbed substance
ene glycol is a potentially hazardous constituent. through and authorised contractor to a licensed
site.
The substance has a boiling point of 107 C, and a
flash point of 121 C. EMERGENCY ACTION
S Fire
It is used as an engine coolant additive, and can be Extinguishing media: CO2, alcohol resistant
found in engine cooling systems, and heat ex- foam, dry powder, or water spray.
changers. Installers, operators and maintainers are Fire fighters to use self contained breathing
likely to encounter this substance. apparatus. Keep fire exposed containers cool.
Prevent run−off from entering waterways,
HAZARDOUS REACTIONS drains and drinking water supplies.

Ethylene glycol is combustible when exposed to S Ingestion

heat or flame and can react vigorously with oxi- Toxic by ingestion. If swallowed induce vomit-
dants. Moderate explosive hazard in form of vapour ing only under the advice of a Doctor or poison
when exposed to heat or flame. Hazardous prod- control centre. Delayed treatment may result in
ucts resulting from combustion or decomposition fatality.
include carbon monoxide, carbon dioxide and acrid S Inhalation (of vapour)
smoke. Self−contained breathing apparatus must Remove from further exposure. In case of ir-
be worn in the event of fume build up. ritation to lungs or throat, seek medical advice.

viL
 S Aspiration (inhalation of liquid) Avoid strong oxidising agents, e.g. chlorates which
Obtain immediate medical assistance. may be use in agriculture.
S Eyes Gas oil is slightly irritating to the skin and has a de−
Flush copiously with water or preferably eye− fatting action. Toxicity following single exposure to
wash solution for at least five minutes. Seek high level of gas oil is of low order. Prolonged, re-
medical advice. peated skin contact may de−fat the skin resulting in
S Skin possible skin irritation and dermatitis. In some
Wash thoroughly with soap and water, and cases warty, cancerous growths have occurred.
seek medical attention if irritation develops.
Change clothing if necessary and wash before PROTECTIVE MEASURES
re−use.
Ensure good ventilation and avoid heat sources.
S Spillage Observance of good housekeeping rules will en-
Soak−up using an absorbent material and dis- sure general safety. Do not smoke. Avoid breathing
pose of this as directed under Storage/Trans- mist.
port.
When working on, or testing, injection equipment,
GAS OIL special care is required to avoid perforation of skin
by high pressure fuel. Use eye protection in the
This product is also known as Red Diesel, Fuel Oil, event of suspected high pressure leak.
and type A1 or A2. It can be pale red or a clear liquid
with a characteristic mild odour. It contains catalyti- Adopt a high standard of personal hygiene. In the
cally cracked oil, petroleum distillates, quinizarin, case of skin contact, wash well with soap and water.
and gas oil maker dye red. The catalytically cracked
oil and petroleum distillates are potentially hazard- Use glove and overalls, and eye protection goggles
ous constituents. if there is a risk of splashing. Use oil impervious
gloves and avoid contamination inside the gloves.
The substance has an initial boiling point of 180C, If overalls become contaminated, discontinue use
a flash point greater than 56C, and a vapour pres- and clean thoroughly. Contaminated clothing
sure less than 0.7mm Hg at 20C and has negligible should be removed, soaked with water, and laun-
solubility in water. dered before re−use.

It is used as a fuel for off−road diesel powered ve- No special respiratory precautions are necessary in
hicles and stationary engines, and can be found in normal use.
fuel tanks, pipes and injection systems. The sub-
DO NOT use as a solvent for removing dirt/grease
stance should not be used for any other purpose
etc, from skin.
without contacting the manufacturer or supplier. In-
stallers, operators and maintainers are likely to en- STORAGE/TRANSPORT
counter this substance.
Store and transport only in correctly marked con-
HAZARDOUS REACTIONS tainers. Keep containers closed when not in use.
Keep cool, out of sunlight and away from naked
This liquid is flammable. Avoid smoking, heat flames. Electrical continuity is required between the
sources, such as welding and naked flames, transport and storage vessels during product trans-
sparks and static electricity build−up. Thermal de- fer.
composition products are hazardous, containing
COX, NOX and SOX compounds. Contain leak/spill with sand, earth or other suitable
material, and prevent entry of substance into drain-
The vapour is explosive. High vapour concentra- age/sewerage system, water−courses and land.
tions can cause respiratory irritation, dizziness, Dispose of unwanted or absorbed substance
nausea, and loss of consciousness. Excessive and through an authorised contractor to a licensed site.
prolonged exposure to the mist can cause chronic
inflammatory reaction of the lungs and a form of Inform local and fire authorities should the product
pulmonary fibrosis. reach waterways, drains etc.

viiL
 EMERGENCY ACTION It has a boiling point greater than 150C, a flash
point Open Cup of 220C (Cleveland), and is insol-
S Fire uble in cold water.
Extinguishing media:
Large fire − Foam/water fog. Never use water It is used in engine lubricant oil systems, sump pan
jet. and filters, make−up tanks and piping systems as a
Small fire − foam/dry powder, AAAF, CO2, lubrication oil for use in wide range of diesel en-
sand, earth. gines operating under severe conditions. Installers,
Avoid making sparks. Fire fighters to use self− operators and maintainers are likely to encounter
contained breathing apparatus. Keep fire ex- this product.
posed containers cool, using water fog/spray.
Prevent run−off from entering waterway, HAZARDOUS REACTIONS
drains and drinking water supplies.
This product is stable although slightly re−active
S Ingestion with oxidising agents. Results of decomposition are
Do not induce vomiting. Wash the mouth out carbon oxides (CO, CO2) and water.
with water, and send to hospital immediately.
Although harmful if swallowed or aspirated
S Inhalation (of vapour) (breathed in), repeated or prolonged exposure is
Remove from further exposure. Obtain medi- not known to aggravate medical conditions.
cal assistance immediately.
Used oil may contain harmful combustion by−prod-
S Aspiration (inhalation of liquid) ucts and unburnt fuel that will cause skin reactions
If, following ingestion of gas oil, vomiting oc- as detailed for fuel. Particular care must be taken if
curs, there is danger of aspiration into the oil form a severely overheated engine is handled −
lungs. This would cause intense local irritation use impervious gloves, lab coat and safety glasses.
and chemical pneumonitis that can be fatal.
Obtain immediate medical assistance. Do not breathe vapour/spray.
S Eyes PROTECTIVE MEASURES
Irrigate copiously with water or preferably eye−
wash solution for at least five minutes. If irrita- Ensure good ventilation and avoid heat sources.
tion persists seek medical advice.
Adopt a high standard of personal hygiene. In case
S Skin of skin contact, wash thoroughly with soap and wa-
Wash thoroughly with soap and water. Change ter.
clothing if necessary.
If high pressure injection has occurred prompt Use safety glasses, impervious gloves and lab
surgical attention is required. coat. Avoid contamination inside the gloves. If
overalls become contaminated, discontinue use
S Spillage
and clean thoroughly.
Absorb using sand, earth or other suitable ma-
terial. Dispose of unwanted or absorbed flam- No special respiratory precautions are necessary in
mable material as directed under Storage/ normal use. Do no breathe vapour/spray when
Transport. handling hot materials.

LUBRICATION OIL − PREMIUM BLUE E STORAGE/TRANSPORT

15W40
Store and transport only in correctly marked con-
tainers. Keep containers tightly sealed when not in
Also known as oil, lube oil, sump oil, new oil is dark, use. Keep in a cool, well ventilated area, out of sun-
viscous liquid with a slight, characteristic odour. light and away from naked flames. Store well away
The base oil contains: distillates (petroleum), sol- from food−stuffs and drinking water.
vent−dewaxed heavy paraffinic. It is not classified
as dangerous according to Directive 1999/45/EC Wear splash goggles, full suit, boots and gloves.
and its amendments, and is not classified accord- Absorb leak/spill with an inert material and dispose
ing to the EU regulations. of unwanted or absorbed substance through an au-

i[
thorised contractor to a licensed site. Finish clean- S Inhalation (of vapour)
ing by spreading water on the contaminated sur- Remove from further exposure. Obtain medi-
face and allow to evacuate through the sanitary cal attention.
system.
S Aspiration (inhalation of liquid)
Obtain immediate medical assistance.
EMERGENCY ACTION
S Eyes
S Fire
Flush copiously with water or preferably eye−
Extinguishing media:
wash solution for at least fifteen minutes. Ob-
Large fire − Use water spray, fog or foam. Do
tain medical advice.
not use water jet.
Small fire − Use dry chemical powder or CO2 S Skin
Fire−fighters to use self contained breathing Wash thoroughly with soap and water. Obtain
apparatus and full turnout gear. Keep fire ex- medical advice if irritation develops. Change
posed containers cool. clothing if necessary and wash before re−use.
S Ingestion S Spillage
Do not induce vomiting, Obtain medical advice Absorb with an inert material and dispose of
immediately. this as directed under Storage/Transport.

x
 Generator Set Warning Labels
Warning signs are provided on the generator set at or near the point of risk. To avoid injury,
always take the necessary precautions – as indicated on the sample signs shown below:

Caution / Warning.
Indicates a risk of
personal injury.

Caution / Warning of Temperature Hazard.

Indicates a risk of personal injury from high temperature.

Caution / Warning of High Voltage Hazard.

Indicates a risk of personal injury from electric shock/electrocution.

Caution / Warning.
Indicates a risk of personal injury from equipment that may be subject to
automatic starting or remote starting.

Caution / Warning.
Indicates to read Operator manual for additional information.

Caution / Warning of Belt and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.

Caution / Warning of Pressure Hazard.

Indicates a risk of personal injury from
pressurized fluids.

Mobile-8

xL
THIS PAGE LEFT INTENTIONALLY BLANK
1. Introduction
ABOUT THIS MANUAL

This is the Service Manual for the generator sets

(gensets) listed on the front cover.

WARNING This genset is not a life support sys-

tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A per-
sonal attendant, redundant power or alarm sys-
tem must be used if genset operation is critical.
[The engine family designation, engine displacement, state-
ment of compliance with applicable EPA and / or California
emissions regulations appear in this block on the actual name-
plate on the genset.]
WARNING Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.

Unauthorized modifications or replacement of

fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.

NAMEPLATE

Be ready to provide the genset model and serial

numbers on the nameplate when contacting Onan
for parts, service or information. Figure 1-1 illus-
trates the nameplate and its location. The gray FIGURE 1-1. TYPICAL NAMEPLATE
boxes illustrate where to look for the model and seri-
al numbers.

1-1
 TYPICAL GENSET cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
Figure 1-2 illustrates the fuel, battery, remote con- shown are the combustion air inlet and oil drain
trol and AC output connection points, the flow of openings in the base.

AC OUTPUT AND REMOTE MAINTENANCE FUEL EXHAUST

CONTROL CONNECTIONS ACCESS CONNECTIONS CONNECTIONS

CONTROL BATTERY
PANEL CONNECTIONS

COOLING & VENTILATING AIR IN HOT AIR OUT

FIGURE 1-2. TYPICAL GENSET

1-2
2. Operation

FUEL RECOMMENDATIONS S B5 Bio−diesel fuel that meets industry specifi-

cations and quality is suitable for use with this
WARNING Diesel fuel is combustible and can genset.
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such ENGINE OIL RECOMMENDATIONS
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi- Oil performance
class ABC fire extinguisher handy.

High quality diesel fuel is necessary for good perfor- Use API (American Petroleum Institute) classified
manace and long engine life. engine oils according to the following guidelines:

S Emissions−Regulated Areas: It is mandatory to

use CF, CF−4, CG−4, CH−4 or CI−4 class oil
S The specifications for the type and sulfur con- with low sulfur fuel (sulfur content less than 500
tent (ppm, % weight) of the diesel fuel used ppm, 0.05% weight) or ultra low sulfur fuel (sul-
must comply with all emissions regulations ap- fur content less than 15 ppm 0.0015% weight).
plicable in the areas where the geneset is to be
operated. S Non−Regulated Areas: CF class oil is recom-
S Diesel fuels meeting ASTM D975 or EN 590 mended when using high sulfur fuel−sulfur con-
specifications are recommended. Use Grade tent between 500 ppm (0.05% weight) and
1−D diesel fuel where ambient temperatures 5000 ppm (0.5% weight). If CF−4, CG−4, CH−4
are below 14 F (−10 C). A minimum Fuel Ce- or CI−4 class oil is used, the oil and oil filter
tane Rating of 45 is recommended. Where am- must be changed twice as often as specified in
bient termperatures are below −4 F (−20 C), or the PERIODIC MAINTENANCE SCHEDULE
the elevation is above 5000 ft (1500 m), a mini- (Page 3−1).
mum Centane Rating of 50 is recommended.
S Non−Regulated Areas: Use CF, CF−4, CG−4,
S Current US EPA regulations for Non−Road en-
CH−4 or CI−4 class oil when using high sulfur
gines limit diesel fuel sulfur content to a maxi-
mum of 500 ppm (0.05% weight). Therefore, fuel−sulfur content between 5000 ppm (0.5%
use Grade 2−D S500 or 2−D S15 diesel fuel. weight) and 10,000 ppm (1.0% weight). The oil
Where ambient temperatures are below 14 F and oil filter must be changed twice as often as
(−10C), use Grade 1−D S500 or 1−D S15 die- specified in the PERIODIC MAINTENANCE
sel fuel. Note that beginning in year 2010. US SCHEDULE (Page 3−1)
EPA regulations for Non−road engines will limit
diesel fuel sulfur content to a maximum of 15
ppm (0.0015% weight) Oil viscosity
S Do not use diesel fuel having a sulfur content
greater than 10,000 ppm (1.0% weight) Look for the SAE (Society of Automotive Engineers)
S Diesel fuel must meet the ASTM D975 stan- viscosity grade. Referring to Figure 2−1, choose the
dard for lubricity and pass a minumum load lev- viscosity grade appropriate for the ambient temper-
el of 3100 grams as measured by ASTM atures expected until the next scheduled oil change.
D6078, or maximum scar diameter of 0.45 mm Multi−grade oils such as SAE 15W−40 are recom-
as measured by ASTM D6079 or ISO 12156−1. mended for year−round use.

2-1
 that is low in minerals and corrosive chemicals. Dis-
tilled water is best.

See Section 14. Specifications for coolant capacity.

See Section 14. Specifications for oil capacity.

STARTING BATTERIES

The genset requires a 12 volt battery to power its

control and starting circuits. Reliable genset starting
FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE and starter service life depend upon adequate bat-
RECOMMENDED COOLANT tery system capacity and maintenance.

Use the best quality ethylene glycol antifreeze solu- See MAINTAINING THE BATTERY AND BATTERY
tion available. It should be fully formulated with rust CONNECTIONS (p. 3-5) and Section 14. Specifi-
inhibitors and coolant stabilizers. Use fresh water cations for minimum required battery ratings.

2-2
 CONTROL PANEL (Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
The control panel (Figure 2-2) has the following fea- chambers. The genset controller automatically var-
tures: ies the time based on engine temperature.)
Control Switch − This switch is used to start and Line Circuit Breaker(s) − The line circuit breakers
stop the genset, prime the engine fuel system and protect the AC power leads connected to the gen-
restore the fault code (blinking status light). set.

Status Lamp − This is a lamp in the control switch Coolant Recovery Tank Fill Cap − The recovery
that blinks rapidly during preheat and cranking. It tank provides for coolant expansion. Replenish the
stays on continuously while the genset is running. If normal loss of coolant by filling here.
the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see Hour Meter − The hour meter records the total run-
Section 12. Troubleshooting). ning time of the genset. It cannot be reset.

LINE CIRCUIT COOLANT RECOVERY

BREAKER(S) TANK FILL CAP

COOLANT RECOVERY
TANK FLUID LEVEL

CONTROL SWITCH
&STATUS LAMP

HOUR METER

FIGURE 2-2. CONTROL PANEL

2-3
 REMOTE CONTROL PANELS
There probably is a remote genset control panel in-
side the vehicle. Onan offers three remote control
kits as follows:
S Remote switch / status lamp (Figure 2-3).
S Remote switch / status lamp and hour meter
(Figure 2-4).
S Remote switch / status lamp and DC voltmeter FIGURE 2-3. REMOTE SWITCH
(Figure 2-5).
The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
the indicator consistently stays above or below the
normal zone, see MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 3-5).

FIGURE 2-4. REMOTE SWITCH / HOUR METER

FIGURE 2-5. REMOTE SWITCH / DC VOLTMETER

2-4
 WARNING EXHAUST GAS is deadly. All en- 4. Turn off air conditioners and other large ap-
gine exhaust contains carbon monoxide; an pliances.
odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms PRIMING THE FUEL SYSTEM
of carbon monoxide poisoning include:
The fuel system should be primed after replacing
 Dizziness  Headache the fuel filter or running the genset out of fuel. To
 Nausea  Weakness and Sleepiness prime the fuel system, hold the control switch down
 Vomiting  Inability to Think Coherently in its Stop position for half a minute.
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If MANUAL STARTING
symptoms persist, seek medical attention. Shut
The genset can be started and stopped from the
down the genset and do not operate it until it has
genset control panel or from a remote panel.
been inspected and repaired.
1. Perform the PRE-START CHECKS, prime the
Never sleep in the vehicle while the genset is fuel system if necessary, and turn off the air
running unless the vehicle has a working car- conditioners and other large electrical loads.
bon monoxide detector. The exhaust system
must be installed in accordance with the genset 2. Visually inspect for fuel, exhaust and coolant
Installation Manual. Make sure there is ample leaks. Do not start the genset if there is a fuel,
fresh air when operating the genset in a con- exhaust or coolant leak and have it repaired.
fined area. 3. Push and hold Start until the genset starts. The
status lamp will come on when the genset starts
PRE-START CHECKS and will stay on while it runs. While starting it will
blink rapidly indicating preheating and crank-
Before the first start of the day and after every eight
ing. (Depending on how cold it is, preheating
hours of operation, inspect the genset as instructed
can take up to 15 seconds, extending the time
under GENERAL INSPECTION (p. 3-2). Keep a log
that the lamp blinks.)
of maintenance and the hours run and perform any
maintenance that may be due. See Returning the CAUTION Excessive cranking can over-
Genset to Service (p. 2-8) if the vehicle has been in heat and damage the starter motor. Do not
storage. crank for more than 30 seconds at a time.
Before each start: Wait at least 2 minutes before trying again.

1. Make sure all vehicle carbon monoxide (CO) 4. See Section 12. Troubleshooting if the genset
detectors are working. does not start after several tries.

2. Check for signs of fuel and exhaust leaks and 5. Let the genset warm up a few minutes until it is
damage to the exhaust system. running smoothly before connecting the ve-
hicle electrical loads (appliances).
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s MANUAL STOPPING
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects. Run the genset under no load for a few minutes to
Repark the vehicle if necessary and/or remove allow the engine to cool down and then push and re-
any objects blocking the air inlet or air outlet. lease Stop.

2-5
 AUTOMATIC STARTING AND STOPPING To avoid overloading the genset and causing shut-
downs, compare the sum of the loads of the ap-
The vehicle may be equipped with an inverter-char- pliances that are likely to be used at the same time to
ger or other automatic genset starting device. Al- the power rating of the genset. It may be neces-
ways follow the instructions and safety precautions sary to run fewer appliances at the same time—
provided by the manufacturer of the automatic start- the sum of the loads must not be greater than
ing device when enabling automatic genset starting. genset rating.

WARNING EXHAUST GAS is deadly. MOV- The genset may shut down due to overload when a
ING PARTS and ELECTRICITY can cause severe large motor or air conditioner is started or cycles off
personal injury or death. To reduce exposure to and then on again, even though the sum of the loads
these hazards, always disable automatic genset is less than genset rating. The reason for this is that
starting before: a motor’s startup load is much larger than its running
load. It may be necessary to run fewer ap-
S Sleeping in vehicle, unless vehicle has a pliances when large motors and air condition-
working CARBON MONOXIDE detector ers are cycling on and off.
S Parking vehicle in garage or confined space
Maximum power decreases as altitude increases
S Parking vehicle for storage because air density decreases. For every 1000-foot
S Servicing genset (305 m) increase in elevation you can expect power
to decrease approximately 3.5 percent. Table 2-1
S Servicing batteries shows the results of typical calculations. It may be
S Servicing electrical appliances necessary to run fewer appliances at higher alti-
tudes.
S Fueling vehicle
TABLE 2-1. POWER VS. ALTITUDE
LOADING THE GENSET
Elevation above Sea
Maximum Power
Level
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- at/below 500 ft (152 m) 12,000 W (rated)
pliances. How much appliance load* can be pow- at 2500 ft (762 m) 11,280 W
ered depends upon the genset power rating. The
at 5500 ft (1676 m) 10,200 W
genset will shut down or its circuit breakers will trip if
the sum of the loads exceeds genset power. See above 5500 ft (1676 m)
10,200 W minus 360 W
Section 12. Troubleshooting. every 1000 ft (305 m)

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

2-6
 RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (Page 2-1). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (Page 2-1).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (Page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE

WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (Page 2-6).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power genset compartment. Keep the genset clean.
must have an approved device to keep the genset
and utility from being interconnected. See the gen- 2. Perform air cleaner maintenance more often.
set Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
WARNING Interconnecting the genset and the 3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (Page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.

2-7
 BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker OFF
hours. See LOADING THE GENSET (Page 2-6). (Page 2-7).
3. Change the engine oil and attach a tag indicat-
Proper engine oil and oil level are especially critical ing oil viscosity. See ENGINE OIL REC-
during break-in because of the higher engine tem- OMMENDATIONS (Page 2-1).
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during 4. Disconnect the battery cables (negative [−]
break-in. See ENGINE OIL RECOMMENDATIONS cable first) from the starting battery and store
(Page 2-1). Check oil level twice a day or every the battery according to the battery manufac-
4 hours during the first 24 hours of operation and turer’s recommendations. See MAINTAINING
change the oil and oil filter after the first 50 hours of THE BATTERY AND BATTERY CONNEC-
operation. TIONS (Page 3-5).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(Page 2-6). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-1).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (Page 3-5).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
STORING THE GENSET (Page 3-5).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (Page 3-2).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(Page 2-7) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.

2-8
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- any engine repair establishment or individual. How-
mance and long genset life. Use Table 3-1 as a ever, warranty work must be completed by an au-
guide for normal periodic maintenance. In hot and thorized Onan dealer.
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Maintenance, replacement or repair of emission nect the negative (−) cable at the battery to pre-
control devices and systems may be performed by vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE TASK After Every

Every Every Every Every Every
First 50 1500 Page
Day Month 250 Hrs 500 Hrs 800 Hrs
Hrs Hrs
General Inspection  3-2
Check Engine Oil Level  3-2
Check Engine Coolant Level  3-10
Check Battery & Battery Connections1  3-5
Change Engine Oil & Oil Filter1, 2, 3   3-3
Check Primary V-Belt Tension4, 7  8-1
Clean Spark Arrestor3, 7  3-7
Replace Engine Air Filter2, 3  3-6
Replace Fuel Filter3  3-9
Adjust Engine Valve Lash7  9-1
Flush Coolant System5  3-10
Replace Coolant Pressure Cap5  3-10
Replace V-Belts & Coolant Hoses6, 7  8-1
Check Fuel Injector Pressure7, 8  9-1
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Tighten or replace the belt (the one closest of the two to the engine) in accordance with the Service Manual if it can be
deflected more than 1/2 in (12 mm) by thumb. (The tension on the front belt is automatically adjusted.)
5. Perform at least once every two years.
6. Perform at least once every five years.
7. Must be performed by trained and experienced personnel (authorized Onan service representatives).
8. EPA requirement.

3-1
 GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.

Oil Level Fuel System

Check for leaks at hose, tube and pipe fittings in the
Check engine oil level (Figure 3-1). fuel supply system while the genset is running and
while it is stopped. Check flexible fuel hose sections
Engine Coolant System for cuts, cracks, and abrasions. Make sure the fuel
line is not rubbing against other parts. Replace worn
CAUTION Operating the genset when coolant or damaged fuel line parts before leaks occur.
level is low can cause serious engine damage.
WARNING Diesel fuel leaks can lead to fire. Do
Check the engine coolant level and look for coolant not operate the genset if operation causes fuel
leaks around the bottom of the genset and on the to leak.
ground below. Minor leaks that can be replenished
by daily additions of coolant to the recovery tank Prime the fuel system if the genset ran out of fuel.
should be repaired by a qualified service technician
as soon as possible. Larger leaks are cause for Battery Connections
shutting down the genset until it can be repaired. Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
Exhaust System electrical resistance which makes starting harder.
See MAINTAINING THE BATTERY AND BATTERY
WARNING EXHAUST GAS IS DEADLY! Do not CONNECTIONS (p. 3-5).
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being Mechanical
drawn into the vehicle.
Visually inspect genset for mechanical damage. For
Look and listen for exhaust system leaks while the generator sets with a sound shield, install service
genset is running. Shut down the genset if a leak is doors before running the generator set to listen for
found and have it repaired before operating the gen- unusual noises. Check the genset mounting bolts.
set again. Check to see that the generator set air inlet and out-
let openings are not clogged with debris or blocked.
Look for openings or holes between the genset Keep the generator set compartment clean.
compartment and vehicle cab or living space if the
To prevent overheating and to reduce fouling with
genset engine sounds louder than usual. Have all
dust and debris, make sure the genset’s normal
such openings or holes closed off or sealed to pre-
ground clearance is not being reduced by sloping
vent exhaust gases from entering the vehicle.
ground, curbs, logs or other objects. Repark the ve-
hicle if necessary and/or remove any objects block-
Replace dented, bent or severely rusted sections of
ing the air inlet or air outlet.
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the CHECKING ENGINE OIL LEVEL
vehicle.
WARNING State and federal agencies have de-
WARNING Do not park the vehicle in high grass termined that contact with used engine oil can
or brush. Contact with the exhaust system can cause cancer or reproductive toxicity. Avoid
cause a fire. skin contact and breathing of vapors. Use rub-
ber gloves and wash exposed skin.
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such WARNING Engine components (drains, filters,
as walls, snow banks, high grass and brush and oth- hoses, etc.) will be hot and can cause severe
er vehicles can cause exhaust gases to accumulate burns. The use of protective gloves is recom-
in and around the vehicle. mended.

3-2
 WARNING Accidental or remote starting can WARNING Accidental or remote starting can
cause severe personal injury or death. Discon- cause severe personal injury or death. Discon-
nect the negative (−) cable at the battery to pre- nect the negative (−) cable at the battery to pre-
vent starting while working on the genset. vent starting while working on the genset.

WARNING Do not run the genset with the main- WARNING Do not run the genset with the main-
tenance access covers off. Contact with hazara- tenance access covers off. Contact with hazar-
dous moving parts and hot exhaust manifolds douse moving parts and hot exhaust manifolds
can cause severe personal injury. can cause severe personal injury.
1. Park the vehicle on level ground, shut down the
genset and remove the front access door. Refer to Table 3-1 for scheduled engine oil change.
2. Pull out the oil dip stick, wipe it clean, reinsert Change oil more often in hot and dusty environ-
it and pull it out again to check the oil level (Fig- ments.
ure 3-1). 1. Place a pan under the oil drain plug (Fig-
3. Add or drain oil as necessary. See REC- ure 3-1), run the genset until warm and shut it
OMMENDED ENGINE OIL (p. 2-1). Keep the off.
oil level between the FULL and ADD marks. 2. Remove the front access door and the oil fill
CAUTION Too much oil can cause high oil cap, unscrew the oil drain plug and drain all the
consumption. Too little oil can cause severe oil from the engine. Reinstall the oil drain
engine damage. Keep the oil level between plug according to the specifications listed
the FULL and ADD marks. in the Bolt Torques table on page 13−1.
4. Reinsert the dipstick and secure the oil fill cap 3. Spin off the oil filter canister and clean the filter
and front access door. mounting surface on the engine block. Remove
the old gasket if it remains.
CHANGING ENGINE OIL AND OIL FILTER
4. Make sure the gasket is in place on the new fil-
WARNING State and federal agenices have de- ter and apply a thin film of clean oil to the gas-
termined that contact with used engine oil can ket. Spin the new filter on until the gasket just
cause cancer or reproductive toxicity. Avoid touches the block. Turn it an additional 1/2 to
skin contact and breathing vapors. Use rubber 3/4 turn. Do not overtighten.
gloves and wash exposed skin. 5. Refill with 5.9 quarts (5.6 liters) of oil, check oil
level (Figure 3-1) and secure the front access
WARNING Engine components (drains, filters,
door.
hoses, etc) will be hot and can cause servere
burns. The use of protective gloves is recom- 6. Dispose of the used oil and oil filter according
mended. to local environmental regulations.

3-3
 FILTER

DIP STICK

FILL CAP

DRAIN PLUG
(22 MM HEX HEAD)

FIGURE 3-1. ENGINE OIL MAINTENANCE

3-4
 MAINTAINING THE BATTERY AND REPLACING THE AIR FILTER ELEMENT
BATTERY CONNECTIONS
WARNING Engine components (drains, filters,
WARNING Arcing at battery terminals or in hoses, etc) will be hot and can cause severe
light switches or other equipment, and flames or burns. The use of protective gloves is recom-
sparks, can ignite battery gas causing severe mended.
personal injury—Ventilate battery area before
working on or near battery—Wear safety WARNING Do not run the genset with the main-
glasses—Do not smoke—Switch work light ON tenance access covers off. Contact with hazar-
or OFF away from battery—Stop genset and dis- douse moving parts and hot exhaust manifolds
connect charger before disconnecting battery can cause severe personal injury.
cables—Disconnect negative (−) cable first and
reconnect last. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Refer to Table 3-1 for scheduled battery mainte- nect the negative (−) cable at the battery to pre-
nance, and follow the battery manufacturer’s in- vent starting while working on the genset.
structions. Have the battery charging system ser-
viced if DC system voltage is consistently low or Refer to Table 3-1 for scheduled air filter replace-
high. Always: ment. Replace it more often in dusty environments.
1. Keep the battery case and terminals clean and
dry and the terminals tight. The air filter is accessible through the front access
door (Figure 3-2). Loosen the three screws that se-
2. Remove battery cables with a battery terminal cure the coolant recovery tank to the housing top
puller. panel and move it out of the way. Loosen the two
3. Make sure which terminal is positive (+) and screws that secure the air filter housing to the hous-
which is negative (−) before making battery ing top panel so that the spring clips that secure the
connections, always removing the negative (−) filter housing end cap can be unlatched. Remove
cable first and reconnecting it last to reduce the end cap and replace the filter element. Secure
arcing. the filter housing, coolant tank and access door.

3-5
 COOLANT
RECOVERY TANK AIR FILTER HOUSING
(SHOWN CUT AWAY) END CAP

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

3-6
 CLEANING THE SPARK ARRESTOR 1. Remove the top enclosure panel.

Refer to Table 3-1 for scheduled cleaning of the 2. Remove the cleanout plug from the muffler. Se-
spark arrestor muffler (which meets U.S. Forest cure the top enclosure panel before running the
Service requirements). Cleaning is required for genset. With the cover in place there will be
maximum genset performance. enough air flow to cool the engine properly and
WARNING A hot muffler can cause severe carry the soot out of the compartment.
burns. Let the muffler cool down before remov-
ing or installing the cleanout plug. 3. Start the genset and load it nearly to full power.
Let the genset run for about five minutes to ex-
The muffler is mounted inside the genset housing pel the soot.
(Figure 3-3). The spark arrestor cleanout plug is lo-
cated on the side of the muffler and is accessible by 4. Stop the genset, allow the muffler to cool down,
removing the top enclosure panel. Clean out the reinstall the cleanout plug and secure the top
muffler as follows: panel.

CLEANOUT PLUG
(11/16 INCH HEX HEAD)

REMOVE THIS PANEL

FOR ACCESS

MUFFLER

FIGURE 3-3. SPARK ARRESTOR CLEANOUT PLUG

3-7
 REPLACING THE FUEL FILTER Removing the Fuel Filter
See Table 3-1 for scheduled fuel filter replacement.
Disconnect the two fittings at the filter and remove
A dirty fuel filter may be the cause of a failure to start.
the mounting nut. Apply a wrench on the filter fitting
The fuel filter is accessible through the front access
as well as on the flare nut so as not to stress the fit-
door (Figure 3-4).
ting. Flare nut wrenches should be used on the flare
WARNING Diesel fuel is combustible and can nuts so as not to round the corners on the nuts. Dis-
cause severe personal injury or death. Do not pose of the fuel filter according to local regulations.
smoke near diesel fuel tanks or equipment. (Note: Filter removal will be easier if the filter mount-
Keep flames, sparks, pilot lights, electrical ing bracket screws are removed.)
switches, arc-producing equipment and all oth-
er sources of ignition well away. Keep a type CAUTION Wipe dirt off the fuel hose fittings at
ABC fire extinguisher in the vehicle. the fuel filter before disconnecting the hoses so
as to keep dirt out of the fuel system.
WARNING Close any fuel line shutoff valve be-
fore disconnecting the fuel line from the filter.
Installing the Fuel Filter

WARNING Accidental or remote starting can Rotate the filter half a turn around its mounting stud
cause severe personal injury or death. Discon- if the fittings interfere with the bracket. It only fits one
nect the negative (−) cable at the battery to pre- way.
vent starting while working on the genset.
Connect the fuel fittings before tightening the filter
WARNING Engine components (drains, filters, mounting nut. Take care not to crossthread the fuel
hoses, etc) will be hot and can cause severe fittings. Thread them in by hand and tighten one flat
burns. The use of protective gloves is recom- past seating with two wrenches.
mended.

WARNING Accidental or remote starting can Prime the fuel system for half a minute to fill the new
cause severe personal injury or death. Discon- filter with fuel.
nect the negative (−) cable at the battery to pre-
vent starting while working on the genset. Secure the access door.

3-8
 HOSE TO FUEL
ENGINE FILTER

FILTER
MOUNTING NUT

BRACKET
HOSE FROM MOUNTING
FUEL PUMP SCREWS

FIGURE 3-4. FUEL FILTER

3-9
 MAINTAINING THE COOLANT SYSTEM remove the coolant drain plug (Figure 3-5) and
drain the coolant into a suitable container.
Refer to Table 3-1 for scheduled maintenance. The
engine cooling system is filled with a 50/50 mixture WARNING Ethylene glycol antifreeze is con-
of ethylene glycol anti-freeze and water when the sidered toxic. Dispose of it according to local
genset leaves the factory, which is suitable for tem- regulations for hazardous substances.
peratures down to -34 F (-37 C).
Flush and clean the cooling system before refilling.
Radiator cleaning chemicals are available at local
Recommended Coolant
auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
See RECOMMENDED COOLANT (p. 2-2).
tion.
Pressure Cap Refilling Cooling System
Replace the pressure cap (Figure 3-5) every two Install the coolant drain plug using pipe thread seal-
years (seals deteriorate and leak). Proper cooling ant. Tighten it just enough so that it does not leak
system pressure (14 psi) is essential for optimal en- when the genset is running and has warmed up. Pull
gine cooling and minimal coolant loss. the hose connected to the pressure cap assembly
out as far and as high as it will go and fill the system
Draining and Cleaning Cooling System with coolant. When the coolant level reaches the fill
opening, start and operate the genset for a few min-
WARNING Hot coolant spray can cause severe utes and shut it down. Add more coolant if neces-
burns. Let the engine cool before releasing the sary and secure the pressure cap.
pressure cap or removing the drain cap.
Fill the recovery tank with coolant mixture to the
WARNING Engine components (drains, filters, COLD mark.
hoses, etc) will be hot and can cause severe WARNING Accidental or remote starting can
burns. The use of protective gloves is recom-
cause severe personal injury or death. Discon-
monded.
nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.
WARNING Accidental or remote starting can
cause severe personal injury or death. Discon- WARNING Coolant trapped in the vent hose
nect the negative (−) cable at the battery to pre- will prevent the system from filling to its capac-
vent starting while working on the genset. ity, which can lead to serious engine damage.
Let the engine cool before removing the pressure Coolant Level Check
cap. Relieve any remaining pressure by turning the
pressure cap slowly, without pushing down. When Check coolant level in the recovery tank (Fig-
the pressure has been relieved, push down on the ure 3-5) before the first startup of each day and fill to
cap, turn it the rest of the way and withdraw it. Then the COLD mark if necessary.

3-10
 PRESSURE CAP
COOLANT RECOVERY AND SYSTEM
TANK FILL OPENING

RECOVERY TANK
FILL CAP (BLUE)

COOLANT
LEVEL

COOLANT DRAIN PLUG

(1/4 INCH HEX SOCKET)

FIGURE 3-5. ENGINE COOLING SYSTEM

3-11
THIS PAGE LEFT INTENTIONALLY BLANK

3-12
4. Preparations for Service
SPECIAL TOOLS S Be prepared for an accident: Keep fire extin-
guishers and safety equipment nearby. Agen-
The following tools are necessary for servicing the cies such as the Red Cross and public safety
genset: departments offer courses in first aid, CPR and
Torque wrench: 0-75 lbs-ft (0-100 N-m) fire control. Take advantage of this information
to be ready to respond to an accident. Learn to
Tachometer be safety-conscious and make safety proce-
Digital multi-meter: AC and DC Voltage, Ohms dures part of the work routine.
Load test panel and leads
TABLE 4-1. HAZARDS AND THEIR SOURCES
SAFETY
 Leaking or spilled fuel
Hazards and Their Sources Fire and
 Hydrogen gas from battery
Explosion  Oily rags improperly stored
There are hazards in servicing gensets. Study Safe-  Flammable liquids improperly
ty Precautions and become familiar with the haz- stored
ards listed in Table 4-1. Note the following safe-  Hot exhaust pipes
guards and ways of avoiding hazards:  Hot engine and generator sur-
Burns
faces
S Use personal protection: Wear appropriate  Electrical shorts
protective safety equipment, such as safety
shoes and safety glasses. Poisonous  Operating genset where ex-
Gas haust gases can accumulate
Do not wear rings or jewelry and do not wear
loose or damp clothing that might get caught  Improper generator connec-
in equipment or conduct electricity. tions
Electrical Shock  Faulty wiring
S Reduce the hazard: A safe, orderly workshop (AC)  Working in damp conditions
area and well-maintained equipment reduce  Jewelry touching electrical
the hazard potential. Keep guards and shields components
in place on machinery and maintain equipment Rotating  Fan or belt guards not in place
Machinery
in good working condition. Store flammable liq-
uids in approved containers; away from fire, Slippery  Leaking or spilled oil
Surfaces
flame, spark, pilot light, switches, arc-produc-
ing equipment and other ignition sources. Keep Heavy  Removing genset from vehicle
the workshop clean and well-lighted and pro- Objects  Removing heavy components
vide adequate ventilation.
S Develop safe work habits: Unsafe actions Testing the Genset Inside a Building
cause accidents with tools and machines. Be
familiar with the equipment and know how to Make sure there is ample fresh air when operating
use it safely. Use the correct tool for the job and the genset inside a building to prevent carbon mon-
check its condition before starting. Comply with oxide asphyxiation.
the warnings in this manual and take special
precautions when working around electrical WARNING EXHAUST GAS IS DEADLY! Engine
equipment. Do not work alone if possible and exhaust must be vented outside if the genset is
take no risks. operated inside a building.

4-1
 REMOVING / INSTALLING GENSET WARNING Diesel fuel is combustible and
can cause severe personal injury or death.
See Section 12 . Troubleshooting to determine the Do not smoke if you are near fuel tanks or
probable cause of the problem before removing the fuel-burning equipment or are in an area
genset for service. The genset is normally mounted sharing ventilation with such equipment.
in a special compartment on the floor of the vehicle Keep flames, sparks, pilot lights, electrical
or on a supporting frame. Contact the vehicle arcs and arc-producing equipment and all
manufacturer or installer if the best way to remove other sources of ignition well away.
the genset is not obvious.
Removal from Vehicle
Disconnections
1. Disable the automatic genset starting feature of Make sure that the genset is firmly supported before
an inverter-charger or other automatic starting loosening any mounting bolts. There are four bolt
device and disconnect the negative (-) battery holes in the skid-base for securing the genset to the
cable from the battery to keep the genset from floor or supporting frame. The lifting eye is accessi-
starting while working on it. Then disconnect ble through the access opening in the top panel of
the battery cables from the genset. the genset.
WARNING Accidental or remote starting
WARNING Gensets are heavy and can cause
can cause severe personal injury or death. severe personal injury if dropped during remov-
Disable the automatic starting feature of an al. Use adequate lifting devices. Keep hands
inverter-charger or other automatic starting and feet clear while lifting.
device and disconnect the negative (−)
cable at the battery to prevent starting while
Installation in Vehicle
working on the genset.

Sparks and high current could cause fire Generally, installation is the reverse of removal and
and other damage to the battery, battery disconnection. Before installing the genset, repair
cables and vehicle if the loose ends of any damage to and seal all hoes in the vapor-tight,
cables connected to the battery touch. Al- fire-resistive barrier between the genset and coach
ways disconnect the negative (−) battery interior. Make sure all mounting screws, and brack-
cable from the battery before disconnecting ets are secure and that all battery, AC output, con-
the battery cables from the genset. trol, exhaust and fuel connections are proper and in
good repair. Perform the service checklist before
2. Disconnect the remote control wiring harness placing the genset in service (Section 15. Service
connector at the genset. Checklist).
3. Disconnect the AC output leads at the genset
terminals. Use four Grade 5 screws (3/8-16 UNC) to secure
the genset to the floor or frame. The screws must
4. Disconnect the exhaust tailpipe from the muf- protrude at least 1/2 inch (10 mm) but not more than
fler flange. 1 inch (25 mm) into the base, as measured from the
5. Disconnect the supply and return fuel lines from bottom surface of the base. Torque the screws to
the genset. 35 lb-ft (41 N-m).

4-2
 TEST STAND WARNING EXHAUST GAS IS DEADLY! Engine
exhaust must be vented outside if the genset is
When testing and servicing the genset on a work- operated inside a building.
bench or test stand make sure the openings in the
skid-base shown in Figure 4-1 (shaded areas) are CAUTION Restricting the air inlet and outlet
free and clear. Also, make sure there is ample fresh openings could lead to damage to the genset
air when operating the genset. due to overheating.

ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉ
AIR
IN

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉAIR
ÉÉÉÉÉÉÉAIR

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉIN
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
OUT

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
FIGURE 4-1. AIR INLET AND OUTLET OPENINGS IN BOTTOM (SHADED AREAS)

4-3
 DISASSEMBLING / REASSEMBLING 2. Remove the two output terminal block mount-
HOUSING AND MOUNTING SYSTEM ing screws to free the output cables from the
panel—preferable to loosening the terminal
Disassembling Housing screws.
3. Loosen the screws that secure the circuit
WARNING Do not operate the genset without breakers to the operator’s console and pull the
the housing panels secured in place. The panels circuit breakers and attached wiring away.
guard against rotating parts and bare live elec- 4. Disconnect the leads at the terminals on the
trical parts that can cause severe personal inju- control switch and hour meter.
ry or death. The housing is also required for
proper genset cooling. 5. Remove the mounting screws to free auxiliary
relays K1, K2 and K3 (p. 11-5)
See Figure 4-2. The housing consists of removable 6. Disconnect the two air intake hoses from the air
panels. The front and top panels include removable intake resonator box.
service doors secured by latches or screws.
7. Remove all attachment screws and pull the
panel away.
Remove all the screws around the perimeter of each
panel and pull the panel away. Note the sets of two Reassembling Housing
and of three screw holes in the top panel which are
circled. These are for the screws that secure the the Reassembly is the reverse of disassembly. To make
air cleaner housing and the coolant recovery tank, sure that all of the panel screw holes will line up, wait
respectively. Remove these screws before lifting to tighten the screws until all of the panels and
the top panel away. screws are in place.

CAUTION The panel screws are all the same When reassembling, torque the panel screws to
length. Do not substitute longer screws to 8 lb-ft (11 N-m).
mount the air cleaner housing or recovery tank.
Note: When securing the side service door frame to
Longer screws can cause damage by bottoming
the panel on its right, the frame and panel should
before becoming tight. touch metal-to-metal. Pull the sound absorbing in-
sulation back a little, if necessary, so that it is not
Because of overlapping flanges, the top panel must pinched between the panel and frame. That way the
be removed to remove the side panels and put back insulation covers the slots in the door frame which
last. would otherwise let some noise out.

To remove the end panel on the generator end of the Reassembling Mounting System
genset:
When reassembling, torque the vibration isolator
1. Cut the wire-tie that secures the wiring har- center and mounting screws according to torque
nesses to the panel. specifications (p. 13-1).

4-4
 AIR CLEANER LIFTING EYE
MOUNTING ACCESS COVER
SCREWS

COOLANT RECOVERY
TANK MOUNTING
SCREWS

AC OUTPUT
TERMINAL
COVER

BRUSH BLOCK
ACCESS COVER

FIGURE 4-2. HOUSING PANELS

4-5
 RADIATOR
ACCESS
COVER

PRIMARY VIBRATION
ISOLATORS (3)

FUEL PUMP
ACCESS
COVER
SECONDARY VIBRATION
ISOLATORS (4)

FIGURE 4-3. MOUNTING SYSTEM

4-6
5. Fuel System
WARNING Accidental or remote starting can FUEL PUMP
cause severe personal injury or death. Before
removing a housing panel or access door, dis- Fuel Flow Test
connect the negative (−) cable at the battery to 1. Disconnect the fuel return hose from the line to
prevent the engine from starting. the supply tank and point the end into a quart
(1 liter) or larger container that has volume
Figure 5-1 shows the components of the fuel system graduations.
up to the connections at the engine.
2. Prime the genset by pushing the Start/Stop
WARNING Diesel fuel is combustible and can switch to STOP and holding it there for the
cause severe personal injury or death. Do not duration of the test. Flow should not be less
smoke near fuel tanks or fuel-burning equip- than 200 ml (0.4 pints) per minute.
ment or are in an area sharing ventilation with 3. If flow is less than specified, replace the fuel fil-
such equipment. Keep flames, sparks, pilot ter. If that does not help, look for other restric-
flames, electrical arcs and switches and other tions in the fuel system. Last, replace the fuel
sources of ignition well away. Keep a type ABC pump. The pump is not serviceable.
fire extinguisher handy.
Removal and Installation
CAUTION Always wipe dirt off fuel fittings be-
fore disconnecting them to keep dirt from enter- The fuel pump is mounted inside the engine mount-
ing the fuel system. ing tower in the base and is accessible by removing
the cover on the side of the base (Figure 4-3).
FUEL INJECTION SYSTEM
Before connecting the fuel lines to the pump, loosen
See Engine Workshop Manual 981-0541 regarding the fuel filter so that there is enough hose length to
fuel injection system service. make connections.

FUEL FILTER Connect the fittings on both ends of the fuel line by
hand before tightening either. Use flare-nut
The fuel filter is mounted on a bracket on the side of wrenches to tighten the fittings so as not to round
the base and is accessible through the front access the corners on the nuts and two wrenches at each
door. See Page 3-8 regarding fuel filter replace- fitting so as not to stress the pump or filter. Tighten
ment. each fitting one flat past seating.

5-1
 INJECTOR PUMP
CONNECTION

FUEL FILTER
FUEL RETURN
CONNECTION
FUEL PUMP

FUEL
RETURN
FITTING FUEL
SUPPLY
FITTING

FIGURE 5-1. FUEL SUPPLY AND RETURN SYSTEM

5-2
6. Air Intake System
WARNING Accidental or remote starting can cess (p. 4-4). To reassemble the air intake system,
cause severe personal injury or death. Before refer to Figure 6-1.
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting. CAUTION Do not cut the engine intake air
tubes to make them “fit better.” Their lengths
Remove the top and back housing panels for ac- are critical for proper noise attenuation.

AIR CLEANER HOUSING—SECURED

TO HOUSING TOP PANEL BY THE 2
SCREWS SHOWN

GENERATOR ENGINE INTAKE

INTAKE COVER AIR RESONATOR

AIR INTAKE
TUBE—ENGINE
AND GENERATOR

FIGURE 6-1. AIR INTAKE COMPONENTS

6-1
THIS PAGE LEFT INTENTIONALLY BLANK

6-2
7. Exhaust System
WARNING Accidental or remote starting can and remove the top and back housing panels
cause severe personal injury or death. Before (p. 4-4).
removing a housing panel or access door, dis- 2. Disconnect the exhaust tail pipe and remove
connect the negative (−) cable at the battery to the flanged tail pipe adaptor.
prevent the engine from starting.
3. Remove the flange screws on both ends of the
The muffler is bolted directly to the outlet flange of flexible tube and withdraw the tube out the end
the engine exhaust manifold and a flexible, corru- of the genset.
gated stainless steel tube is bolted to the muffler
CAUTION The flexible tube is fragile. Take
outlet flange (Figure 7-1). The flange on the other
care not to bend or twist it.
end of the flexible tube is bolted to a bracket on the
base assembly (Figure 8-1). 4. Remove the screws from the 2 muffler support
brackets and the muffler manifold flange and
Flanged tailpipe adaptors are available for tailpipe withdraw the muffler.
connections out the end, back or bottom of the gen-
set. See the Installation Manual for important safety Installation of the muffler is the reverse of removal.
warnings and instructions regarding the routing and Use new flange gaskets for the tail pipe adaptor,
termination of the tailpipe (not supplied by Onan). flexible tube and muffler. Tighten all screws and nuts
according to specifications (p. 13-1).
Always use new flange gaskets when connecting
exhaust system components.
WARNING Exhaust gas is deadly. The exhaust
system must not leak. Liability for injury, death,
damage and warranty expense due to the use of
See Page 3-7 regarding spark arrestor cleaning.
an unapproved muffler or due to modifications
becomes the responsibility of the person instal-
To remove the muffler:
ling the unapproved muffler or performing the
1. Disconnect the negative (-) battery cable from modifications. Use Onan approved exhaust
the battery to prevent the genset from starting system parts.

7-1
FIGURE 7-1. MUFFLER ASSEMBLY

7-2
8. Engine Cooling System
WARNING Accidental or remote starting can 3. Remove the radiator access cover on the back
cause severe personal injury or death. Before of the base (Figure 4-3).
removing a housing panel or access door, dis- 4. Disconnect the two radiator hoses and with-
connect the negative (−) cable at the battery to draw the radiator out the side opening in the
prevent the engine from starting. base.
Refer to Figure 8-1 to reassemble the cooling sys- Installation of the radiator is the reverse of removal.
tem components. Replace the foam sealing strips around the opening
in the base if they are damaged. Tighten all screws
The genset has a liquid-cooled engine with integral,
according to specifications (p. 13-1).
belt-driven coolant pump. The radiator is mounted
horizontally in the base of the genset. The system
drain plug is on the radiator end tank. The coolant
FAN
recovery tank is mounted on the underside of the
Fan: To remove the fan:
top housing panel.
1. Remove the top and end housing panels
The centrifugal blower (fan) is driven by a two-belt, (p. 4-4).
two-stage drive system. The primary belt drives the
2. Remove the four fan hub bolts and withdraw the
coolant pump and battery charging alternator. The
fan and spacer.
coolant pump pulley has two belt groves. The outer
belt grove drives the fan pulley (coupling) that spins
CAUTION The fan (blower wheel) is frag-
freely on bearings on the end of the crankshaft. The
fan is mounted on the coupling with a spacer. ile. Do not brace against it when loosening
or tightening the hub bolts.
The fan pulls cooling air up through the radiator and
across all of the components inside the housing. Fan Coupling: If it is necessary to replace the fan
The warm air is discharged out the bottom opening coupling (pulley) from the end of the crankshaft, use
in the right end of the base. a 1/2 inch socket wrench drive to remove it.

See Page 3-10 regarding periodic cooling system Installation is the reverse of removal. Tighten all
maintenance and Page 9-3 regarding the coolant screws according to specifications (p. 13-1).
temperature sender.
FAN BELT
THERMOSTAT AND PUMP
Primary Belt Tension
See Engine Workshop Manual 981-0541 for coolant
thermostat and pump service. Remove the top genset housing panel (p. 4-4). Ad-
just tension so that deflection is 8-10 mm
RADIATOR (0.3-0.4 inch) midway between the alternator and
pump pulleys when a force of 10 kg (22 pounds) is
To remove the radiator: applied.
1. Disconnect the negative (-) battery cable from
Secondary Belt Tension
the battery to prevent the genset from starting.
2. Let the genset cool down and then drain the The secondary belt has a spring tensioner (Fig-
cooling system (p. 3-10). ure 9-1).

WARNING Hot coolant spray can cause se- Belt Replacement

vere burns. Let the engine cool before re-
leasing the pressure cap or removing the Remove the fan and then install the new belt(s) and
drain cap. adjust tension.

8-1
THIS PAGE LEFT INTENTIONALLY BLANK
 COOLANT
RECOVERY
OVERFLOW TANK
LINE

VENT PRESSURE CAP

LINE AND SYSTEM FILL

INNER SYSTEM
BLUKHEAD FILL HOSE
RADIATOR
HOSES

FAN
SCROLL

FAN

EXHAUST SECONDARY
FLANGE BELTAND PRIMARY
BRACKET TENSIONER BELT RADIATOR

FIGURE 8-1. ENGINE COOLING SYSTEM


THIS PAGE LEFT INTENTIONALLY BLANK
9. Engine and Accessories
WARNING Accidental or remote starting can 3. Remove the blower (fan) assembly (p. 8-1).
cause severe personal injury or death. Before 4. Remove the radiator (p. 8-1) for access to the
removing a housing panel or access door, dis- bolt head of the generator isolation mount.
connect the negative (−) cable at the battery to
prevent the engine from starting. 5. Disconnect the generator cooling air tube from
the generator (p. 6-1).
ENGINE 6. Disconnect the battery cables and base
grounding strap from the engine.
See Engine Workshop Manual 981-0541 for servic-
ing the engine proper: adjusting valve clearance 7. Disconnect the wiring harness lead to the fuel
(lash), servicing the fuel injection system, replacing pump.
the glow plugs, cleaning the crankcase breather as- 8. Disconnect the supply and return fuel hoses at
sembly, replacing the coolant thermostat and pump the engine (p. 5-2).
and overhauling the engine.
9. Disconnect the flexible connector from the muf-
Removal fler outlet flange (p. 7-2).
10. Attach a hoist of sufficient capacity to the lifting
The engine-generator-muffler assembly and wiring eye, take up the slack and remove the center
harnesses can be removed as an assembly from bolts of the three isolation mounts. Lift the en-
the genset if it is necessary to remove either the en- gine-generator_muffler assembly away.
gine (Figure 9-1) or the generator (Figure 10-1). To
do so: Installation
1. Remove all of the housing panels except the in-
Installation is the reverse of removal. Make sure the
ner bulkhead (p. 4-4), leaving the wiring har- air seal ring is in place around the oil drain hole in the
nesses attached to the engine-generator as- base to keep air from bypassing the radiator. (The
sembly. engine-generator compartment is under a partial
2. Drain the cooling system, disconnect the radia- vacuum.) Tighten all screws to specifications
tor and vent hoses from the engine. (p. 13-1).

9-1
THIS PAGE LEFT INTENTIONALLY BLANK
 LIFTING EYE STARTER COOLANT VENT HOSE
FLYWHEEL MOTOR AND TEMPERATURE FITTING
SOLENOID SENDER

OIL FILTER OIL PRESSURE BATTERY

SWITCH CHARGING
(NOT SHOWN) ALTERNATOR

ENGINE TIMING SECONDARY

MARKS AND PIN BELT TENSIONER
ASSEMBLY

FLYWHEEL
HOUSING

OIL HOSES

OIL FILL OIL FILTER

ASSEMBLY ADAPTER
GOVERNOR FREE-SPINNING FAN COUPLING
ACTUATOR (PULLEY) ON CRANKSHAFT

FIGURE 9-1. ENGINE AND ACCESSORIES


THIS PAGE LEFT INTENTIONALLY BLANK
 WARNING Accidental or remote starting can minal) when the engine is not running or if the switch
cause severe personal injury or death. Before does not open when oil pressure rises to 14 psi
removing a housing panel or access door, dis- (96 kPa).
connect the negative (−) cable at the battery to
prevent the engine from starting. BATTERY CHARGING ALTERNATOR

ENGINE SENSORS The battery charging alternator is accessible for ser-

vice by removing the top housing panel (p. 4-4). Ad-
The engine is equipped with a coolant temperature just fan belt tension and tighten the mounting bolts
sender and low oil pressure cutout switch (Fig- according specifications (p. 13-1) when reassem-
ure 9-1). The associated fault codes (Sec- bling.
tion 12. Troubleshooting) are as follows:
S No. 1 - Engine Over Temperature STARTER MOTOR
S No. 2 - Low Oil Pressure The starter motor is accessible for service by re-
S No. 24 - Faulty Engine Temperature Sender moving the top housing panel (p. 4-4). Tighten the
mounting bolts according specifications (p. 13-1)
Coolant Temperature Sender when reassembling.

The sender is accessible for replacement by remov- GLOW PLUGS

ing the top housing panel (p. 4-4). Replace the
sender if resistance is not approximately 1300 ohms Refer to engine Workshop Manual 981-0541 when
in ice water, 700 ohms at room temperature or 57 replacing the glow plugs, which are accessible for
ohms in boiling water. Use thread sealant and en- service by removing the top housing panel.
gage at least two threads when reassembling.
Note: If a glow plug does not come out after un-
Oil Pressure Switch screwing it, or the end has broken off, it will be
necessary to remove the engine head. Glow
The switch is accessible for replacement by remov- plugs can swell if preheat voltage is greater than
ing the top housing panel (p. 4-4). Replace the 14 volts, such as when a battery booster is used
switch if it is not closed (ground continuity at the ter- for starting.

9-
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting. HIGH-IDLE
SPEED STOP
SCREWS
GOVERNOR ACTUATOR

The governor actuator (Figure 9-2) is removeable

by removing the housing end panel (Figure 4-2) and
the fan and inner bulkhead (Figure 8-1). Remove
the actuator from the engine block (2 screws). When
reassembling, make sure the O-ring seal is in place
and that the push rod goes through the internal
guide hole. Replace the actuator if:
S Electrical resistance across its terminals is not
2 to 4 ohms.
S The plunger does not pull in smoothly when B+
(12 VDC) is applied across its leads. GOVERNOR
S The plunger does not move in and out smoothly ACTUATOR
when pushed in by hand.

HIGH-IDLE SPEED

Reset high-idle speed if the stop screw seals have

been broken or internal governor parts have been FIGURE 9-2. GOVERNOR ACTUATOR AND HIGH-
IDLE SPEED STOP SCREW
replaced or are worn. To reset high-idle speed:
1. Remove the governor actuator to allow opera-
tion at full fuel rack, but leave it connected to
keep Fault No. 19 from preventing Start. Plug
the opening to keep oil from splashing out.
2. Disconnect the fuel pump and power it directly
with a 12 volt battery to keep the engine run-
ning when Fault No. 12 or 14 occurs.

WARNING These adjusting screws are in

close proximity to rotating belts and pulleys
that can cause severe personal injury. Be
very careful not to get your hands near the
pulleys and belts while making the adjust-
ments.
3. Disconnect all loads from the genset to protect
them from overfrequency and start the genset.
Adjust the stop screws (Figure 9-2) to obtain
67.3-68.3 Hertz (2019-2049 rpm). TO STOP
THE ENGINE, disconnect the fuel pump from
the battery.
4. Seal the adjusting threads with paint.
5. Re-install all of the components that were re-
moved or disconnected.

9-
10. Generator

WARNING Accidental or remote starting can Testing Winding Resistance

cause severe personal injury or death. Before
removing a housing panel or access door, dis- Use a Digital Ohmmeter to check for open or
connect the negative (−) cable at the battery to shorted Main (Stator), Quadrature or Field Wind-
prevent the engine from starting. ings. Use a Wheatstone Bridge having a precision
of at least 0.001 ohm to measure Stator Winding re-
GENERATOR WINDING TESTS sistance.

Testing Winding Insulation Resistance Replace a rotor or stator that has winding
resistances outside Table 10-1 tolerances.
Testing for Winding-to-Winding and Winding-
to-Ground Shorts: A digital ohmmeter can be used
(highest scale) as a preliminary check for a Stator Windings: Check Stator Winding resistance
grounded Stator, Quadrature or Field Winding or for across the AC output terminal block: TB2-1—TB2-3
a short between Stator (Main) and Quadrature and TB2-2—TB2-3. Make sure circuit breaker
windings. The meter should indicate infinite resist- CB1/CB2 is ON.
ance.
If resistance is within Table 10-1 tolerances, the
A 500 VDC megger is recommended for finding whole AC output circuit is probably sound.
winding-to-winding or winding-to-ground shorts.
Resistance between windings or to ground should If resistance is high, check resistance directly
be not be less than 1 megohm. across the winding leads, which are connected at
CB1/CB2 and at the grounding screw on the gener-
Testing Stator Windings with a Megger: A 500 ator mounting bracket (p. A-3). Service as neces-
VDC megger is recommended for testing Stator sary by tightening connections or servicing the gen-
Winding insulation resistance. Disconnect T2 and erator, AC harness (p. A-3) or circuit breakers
T3 from the grounding screw on the engine mount- (p. 11-5).
ing bracket (p. A-3) to isolate the windings from
ground, and separate the two parts of generator
Field and Quadrature Windings: Separate the
connector P3/J3 to isolate the control board from
two parts of generator connector P3/J3 for access
the DC test voltage. Apply one side of the DC test
to the field windings (P3-7—P3-8) and quadrature
voltage to both windings (connect to either end) and
windings (P3-3—P3-6). Resistance must within
the other side to a good generator ground (stator
Table 10-1 tolerances. If field resistance is high, first
laminations) for 10 minutes and record resistance
service the brushes and slip rings (p. 10-3) and re-
values at one minute and at 10 minutes.
peat the test. Then, if necessary, service the rotor.
A resistance value of at least 5 megohms should be
obtained for a new stator with dry windings. The po- TABLE 10-1. WINDING RESISTANCES
larization index (the ratio of the resistance reading RESISTANCE (OHMS) @ 705 F (215 C)
WINDING
at 10 minutes to the reading at one minute) should HDKCA, HDKCC HDKCB, HDKCD
also be at least 2. For a genset that has been in ser- T1-T2, T3-T4 0.197-0.241 0.178-0.218
vice, the resistance value should not be less than Q1-Q60
1.99-2.42 1.89-2.31
1 megohm, nor the polarization index less than 2. (P3-3 to P3-6)
Rotor
19.4 22.5
If the readings are low, or the genset has been in (P3-7 to P3-8)
storage for a long time in a high-humidity environ- Note: Even though winding resistance may be within the
ment, the test should be repeated after the windings tolerances of this Table, replace the Rotor or Stator if
winding-to-winding or winding-to-ground resistance (wind-
have been dried. The most effective way of drying ing insulation resistance) is less than 1 megohm. (An
the stator windings, if the genset is operable, is to ohmmeter must indicate an open circuit or infinite resistance
run it under full load for at least one hour. between windings or between any winding and ground.)

10-1
THIS PAGE LEFT INTENTIONALLY BLANK
 CONTROL BOARD

GENERATOR
INTAKE
COVER
O-RING

END BELL

THROUGH BOLTS (4)

(thread the ends with
shorter lengths of thread
into the adaptor)

STATOR
ASSEMBLY

ROTOR
BEARING
GENERATOR
LEAD EXIT AND
BRUSH BLOCK ROTOR
ACCESS ASSEMBLY

DRIVE DISC
(assemble with
GUARD chamfered
SCREEN edge out)

ADAPTOR
CASTING

SLIP RINGS
BRUSH BLOCK ASSEMBLY
FAN

FIGURE 10-1. GENERATOR

10-
THIS PAGE LEFT INTENTIONALLY BLANK
 GENERATOR SERVICE
BRUSH LEAD
WARNING Accidental or remote starting can TERMINAL
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting.
Brushes and Slip Rings
Access: Remove the brush block access cover
(Figure 4-2) for access to the brush block assembly
and slip rings.
Checking for Wear: Check brush wear by marking
off a piece of wire at 1 inch (25 mm) and inserting it
into each of the two holes in the top of the brush
block from which the pig tails exit. Replace the brush
if the wire can be inserted more than 1 inch (25 mm). FIGURE 10-2. BRUSH BLOCK ASSEMBLY
(Make sure the wire rests on top of the brush and not
on part of the spring.)
Cleaning Up Slip Rings: If the slip rings are
grooved or pitted, try cleaning them up with a com-
mutator stone while cranking the engine. (Connect
the starter motor directly to a battery and the starter
solenoid to a remote start switch.) The rotor will
have to be removed if the slip ring assembly has to
be replaced.
Replacing Brush Block: When replacing the brush
block assembly, center the brushes on the slip rings
before tightening the two mounting screws. Make
sure to reconnect the lead marked F1 to the out-
board brush and the lead marked F2 to the inboard
brush.

10-
 WARNING Accidental or remote starting can 1. Make sure the chamfered edge of the drive disc
cause severe personal injury or death. Before faces the flywheel.
removing a housing panel or access door, dis- 2. Make sure the ends of the through bolts with the
connect the negative (−) cable at the battery to shorter lengths of thread are threaded into the
prevent the engine from starting. adaptor casting.
Removing the Generator 3. Make sure the O-ring is in place in the bearing
bore of the end bell.
Remove the engine-generator assembly as an as-
4. Relubricate the bearing bore with molybdenum
sembly from the genset (p. 9-1) and then remove
desulfide or an equivalent grease. Cover the
the generator from the engine, as follows:
bearing bore with a thin layer of grease, cover-
1. Remove the air inlet assembly (Figure 10-1). ing both the O−ring and the metallic surface.
2. Disconnect the generator leads attached to the 5. Before securing the the air inlet adaptor assem-
grounding screw on the generator mounting bly, make sure the brush block assembly is in
bracket (Page A-3) and separate the two parts place (Brushes and Slip Rings) and that the
of generator connector P3/J3. wire holding up the brushes has been removed.
3. Remove the brush block assembly or lift the
brushes and insert a wire to keep the brushes
Replacing the Rotor Bearing
up and out of the way while disassembling and Use a gear puller if it is necessary to remove the ro-
reassembling the generator. tor bearing. If the slip ring assembly is being re-
4. Loosen the four through bolt nuts and remove placed, install the new assembly before pressing on
the end bell and stator assemblies. the bearing. Press a new rotor bearing on flush with
the end of the rotor. Apply Loctite #680 adhesive to
Note: Any time the end bell assembly is removed, the the shaft and Loctite #747 activator to the bearing
O−ring located in the bearing bore must be replaced. mating surface.
5. Remove the adaptor casting from the flywheel
housing and then the rotor from the flywheel. Replacing the Slip Ring Assembly

Installing the Generator Remove the rotor bearing and unsolder the two field
leads if it is necessary to remove the slip ring as-
Installation is the reverse of removal. Tighten all sembly. Press a new slip ring assembly on making
nuts and bolts according to specifications (p. 13-1) sure the key is in place and soldered the field leads
and note the following: to the slip ring assembly.

10-
 ADJUSTING VOLTAGE 3. Rapidly press START 6 times. The status lamp
will start to blink once a second to confirm that
The controller has a voltage set mode that is en- the controller is in voltage adjust mode.
abled by rapidly pressing START 6 times during the
first minute after startup. To adjust voltage: 4. To adjust voltage up, press START and re-
1. Disconnect all genset loads and connect accu- lease quickly. Each time START is released,
rate meters to measure AC output voltage. voltage will increase approximately 0.6 volt.
5. To adjust voltage down, press the control
WARNING HAZARDOUS VOLTAGE!
switch to START and release in approximately
Touching uninsulated live parts inside the
1 second. Each time START is released, volt-
genset or connected equipment can result
age will decrease approximately 0.6 volt.
in severe personal injury or death. For your
protection, stand on a dry wooden platform 6. Normal operation will resume in 20 seconds af-
or rubber insulating mat, make sure your ter the last adjustment. The last adjustment will
clothing and shoes are dry, remove jewelry be saved by the controller.
from your hands and use tools with insu-
lated handles.
Note: Voltage adjustments will not be saved if a
2. Start the genset and let voltage and frequency fault shutdown occurs or STOP is pressed while
stabilize for 5 to 10 seconds. in voltage set mode.

10-
THIS PAGE LEFT INTENTIONALLY BLANK

10-
11. Control
WARNING Accidental or remote starting can and harness drawings. The control board is acces-
cause severe personal injury or death. Before sible for replacement through the front access door.
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to Connector: A single connector (P1/J1) is used for
prevent the engine from starting. all connections between the control board and har-
ness. When separating the connector, use a small
CONTROL BOARD (CONTROLLER) flat-bladed screwdriver to lever out the catch.

The Control Board is an integrated microprocessor- CAUTION Makeshift meter test probes used
based engine and generator control that provides all for testing Control Board connections during
the control, monitoring and diagnostic functions re- troubleshooting can damage pin sockets by
quired to operate the genset. spreading or dislodging the contact wiper arms,
resulting in an open or intermittent electrical
Control Board connection. Use a mating pin (PN 323−1605) or a
test probe that is 0.045 inches in diameter. Re-
Location and Mounting: Refer to Figure 11-1 for place damaged pin sockets (PN 323−1614−01).
control board location and mounting and to Make sure the pin sockets are fully seated and
Pages A-1 and A-2 for the control wiring schematic can’t be pulled out.

CONNECTOR
J1

CONTROL
BOARD

GENERATOR
INTAKE COVER

FIGURE. 11-1 CONTROL BOARD

11-1
Major Controller Functions Stopping: Touch the control switch to STOP
(Prime). The Controller:
Figure 11-2 is a block diagram of Controller func-
tions. 1. Disables output voltage.

Initialization: Control initialization consists of 2. Deenergizes the fuel lift pump and governor ac-
checking memory (RAM, ROM, EEPROM) and tuator.
genset configuration.
3. Turns off the status lamp.
Fuel Priming: Press and hold the control switch at
STOP (Prime) for more than 3 seconds to cause 4. Writes session data (number of cranks, min-
fuel pump E2 to prime the fuel system. utes of operation, last fault, etc.) to non-volatile
memory (NVM).
Starting: Press and hold the control switch at
START (Preheat) until the genset starts. The Con- 5. Removes processor power when idle 5 min-
troller: utes.
1. Energizes fuel lift pump E2.
Note: Stop takes precedence over Start if both pres-
2. Energizes the glow plugs (3) during pre-heat ent due to a faulty switch or other cause.
and cranking. The duration of pre-heat prior to
cranking is engine temperature dependent, but
does not exceed 15 seconds. Controlling Voltage: The Controller maintains
3. Enables the status lamp to blink rapidly. nominal AC output voltage as load varies by varying
field voltage. In response to transient loads, it low-
4. Enables some fault detection. ers the voltage setpoint to allow engine recovery.
5. Enables cranking for up to 35 seconds. Field power is supplied by the quadrature windings
(Q1-Q2). See ADJUSTING VOLTAGE (p. 10-5).
6. Enables field flash (F1-F2).
7. Energizes governor actuator E1 (full rack).
8. Disconnects the starter at 800 rpm. Controlling Fuel: The Controller positions the fuel
rack to maintain nominal frequency as load varies
9. When operating speed is reached: by sending a pulse-width-modulated square-wave
signal (PWM) to governor actuator E1. It determines
A. Enables output voltage. frequency by sensing the zero crossings of the
quadrature winding output. When the actuator is not
B. Turns off field flash.
energized, its spring-loaded plunger holds the fuel
C. Turns on status lamp. rack in the no-fuel position.

D. Enables Switched B+ (J1-8).

Fault Monitoring, Shutdown and Diagnostics:
E. Enables complete fault detection. See Section 12. Troubleshooting.

11-2
 COOLANT TEMPERATURE SENDER
LOCAL
CONTROL

OIL PRESSURE SWITCH

FUEL LIFT PUMP

ENGINE

REMOTE STARTER
CONTROL

GLOW PLUGS
CONTROL
BOARD

GOVERNOR ACTUATOR

RS-232
(FACTORY ONLY)

QUADRATURE
& FREQUENCY
SENSE

FIELD GENERATOR

AC VOLTAGE
BATTERY SENSE

AC OUTPUT

FIGURE 11-2. CONTROL BLOCK DIAGRAM

11-3
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before CONTROL RELAYS
removing a housing panel or access door, dis- SWITCH S1 K1, K2, K3
connect the negative (−) cable at the battery to
prevent the engine from starting.

LOCAL AND REMOTE CONTROL

SWITCHES
Refer to Pages A-1 and A-2 for the control wiring
schematic and harness drawings.

Control Switch Tests

Local Control Switch S1: Switch S1 is mounted on
the control panel (Figure 11-3). Unsnap connector
P9, which is accessible through the front access
door. Referring to Figure 11-4, replace the switch if:
S The switch does not close across terminals 2
and 3 when held in the Start position LINE CIRCUIT
HOUR BREAKERS
S The switch does not close across terminals 1 METER M1 CB1 & CB2
and 2 when held in the Stop position
S The status indicator light does light when
12 VDC is connected across terminals 7 (−) FIGURE 11-3. CONTROL COMPONENTS
and 8 (+).

Remote Control Switch: Disconnect remote con-

trol connector J8/P8 and test a remote control
switch (customer supplied) in the same manner as
switch S1 and repair as necessary.

Wiring Harness Tests

If the control switches are good but the Start / Stop
circuit still does not work, test the wiring harness be-
tween the control switches and control board.

Disconnect P1 from the control board (p. 11-1). TERMINALS SCHEMATIC

S P1-9 should close to P1−27 when the local or

remote switch is held in its Start position.
FIGURE 11-4. CONTROL SWITCH S1
S P1-32 should close to P1−27 when the local or
remote switch is held in its Stop position.

Replace broken or missing wires and bent or cor-

roded terminals.

HOUR METER
The hour meter (Figure 11-3) is mounted on the
control panel and is accessible for replacement
through the front access door. It cannot be reset.

11-4
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting.

LINE CIRCUIT BREAKERS CB1, CB2

The line circuit breakers (Figure 11-3) are mounted
on the control panel and are accessible for replace-
ment through the front door. Disconnect all wiring TERMINALS SCHEMATIC
and check electrical resistance across the terminals
of each circuit breaker. Replace a circuit breaker FIGURE 11-5. RELAYS
that does not reset or that does not close or open as
the handle is turned ON and OFF.

RELAYS K1, K2, K3

These relays are secured in a row above the intake
resonator (Figure 11-3) and are accessible for re-
placement by removing the top enclosure panel. To
test a relay, apply 12 VDC across terminals 85−86
(Figure 11-5). Replace the relay if 30−87a (NO)
does not close or 30−87 (NC) does not open, or ei-
ther does not return to its normal position when pow-
er is removed.

See Page A-1 for relay function.

VOLTAGE SENSE TRANSFORMER TX1

The voltage sense transformer is mounted in the top
of the intake resonator (Figure 11-6) and is accessi-
ble for replacement by removing the top enclosure
panel. Disconnect all four leads and check electrical
resistance across the primary and secondary wind-
ings. Replace the transformer if the resistance of ei-
ther winding is not as specified in the schematic.

FIGURE 11-6. VOLTAGE SENSE TRANSFORMER

11-5
THIS PAGE LEFT INTENTIONALLY BLANK

11-6
12. Troubleshooting
TROUBLESHOOTING WITH TABLE 12-1 S 2 Blinks: indicates a low oil pressure fault. For
Example:
To aid troubleshooting the genset controller causes blink−blink−−long pause−−blink−blink−−long pause−−repeat
the status indicator light to blink the numeric code
S 3 Blinks: indicates a service fault. For exam-
assigned to the fault that caused shutdown. For a
ple:
brief description of the fault and step-by-step cor-
blink−blink−blink−long pause−repeat
rective action, refer to TABLE 12-1. TROUBLE-
SHOOTING, which lists the fault codes in numerical S 4 Blinks: indicates that cranking exceeded 30
order. seconds without the engine starting. For ex-
ample:
Many genset shutdowns can be avoided by perform- blink−blink−blink−blink−long pause−repeat
ing periodic maintenance on schedule (TABLE 3-1.
PERIODIC MAINTENANCE SCHEDULE) and by not S Note: Fault Code Nos. 1, 2, 3, and 4 are first level
running the genset out of fuel. Note that when the faults. Pay close attention to the pause se-
genset and propulsion engine draw from the same quence to avoid interpreting first level faults as
fuel tank, the fuel dip tubes are usually arranged so second level Fault Codes Nos. 11, 22, 33, or 44.
that the genset will run out of fuel first. By marking
the genset empty point on the fuel gauge, it will be S Note: Generator systems equipped with an
easier to tell when the genset may run out of fuel. AutoGen Start of AGS feature may experi-
ence shutdowns with no Fault Codes. This
FAULT CODES is because the AutoGen Start control is
sending the generator control a signal that
The genset controller provides extensive diagnos- is sensed as a normal shutdown signal.
tics by causing the status indicator light on the Con-
trol Switch to blink in a coded fashion. Proper proce- Because different fault logics are used on different
dure for obtaining the last recorded fault code: products, refer to the appropriate product’s service
manual to translate the blink code shutdown fault.
1. To wake the control: Press and hold the STOP/ Each fault will have a description of the shutdown
Prime button until the indicator light illuminates (3−4 reason and a list of step bystep corrective actions.
seconds). Then release.
RESTORING FAULT CODE BLINKING
2. Press the STOP/Prime button 3 times within 5
seconds to display the first level shutdown fault The fault code stops blinking after five minutes.
code. The indicator light will repeatedly blink 1, 2, Press Stop three times within three seconds to re-
3,or 4 blinks at a time: store fault code blinking.
S 1 Blink: indicates shutdown due to high engine Note: The last fault logged will blink even though the
coolant temperature. For example: condition that caused the shutdown may have been
blink−−−long pause−−−blink−−−long pause−−−repeat corrected.

12-1
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

NO RESPONSE AT CONTROL SWITCH

(Faulty switch, poor or missing connections, dead battery)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Try the genset (local) control switch if there is no response at the remote control switch, and vice
versa.
 If there is no response at either remote or local switch, go to Step 2.
 If there is no response at the remote switch but at the local, go to Step 3.
 If there is no response at the local switch but at the remote, go to Step 6.
2. Check for 12 VDC across genset battery cable terminal block TB1. If there is no voltage, service
as necessary by cleaning and tightening battery cable connections, recharging or replacing the bat-
tery or replacing damaged or missing battery cables. If there is voltage across TB1, but no response
at either remote or local switch, go first to Step 3, and then, if necessary, also to Step 6.
3. Disconnect harness connector P8 from the remote circuits. Check for B+ (12 VDC) at P8-C (Start)
and at P8-E (Stop) and for ground continuity at P8-A (Ground). If there is B+ and ground continuity,
service the remote switch and harness (p. 11-4). If not, go to Step 4.
4. Disconnect harness connector P1 from the control board (p. 11-1) and check for B+ at P1-10 and
for ground continuity at P1-27. If there is B+ and ground continuity, go to Step 5. If not, go to Step 9.
5. Check for wiring continuity in the harness between connectors P8-C and P1-9 (Start), P8-E and
P1-32 (Stop), P8-B and P1-7 (Status), P8-F and P1-8 (Run) and P8-A and P1-27 (Ground). Repair
as necessary. Make sure connector pin sockets are not damaged or corroded and that they are fully
seated and can’t be pulled out. Replace the control board (p. 11-1) if the genset still does not start.
6. Disconnect harness connector P9 from control switch S1 (p. 11-4). Check for B+ (12 VDC) at P9-3
(Start) and at P9-1 (Stop) and for ground continuity at P9-2 (Ground). If there is B+ and ground conti-
nuity, test control switch S1 and replace if necessary (p. 11-4). If not, go to Step 7.
7. Disconnect harness connector P1 from the control board (p. 11-1) and check for B+ at P1-10 and
for ground continuity at P1-27. If there is B+ and ground continuity, go to Step 8. If not, go to Step 9.
8. Check for wiring continuity in the harness between connectors P9-3 and P1-9 (Start), P9-1 and
P1-32 (Stop), P9-8 and P1-7 (Status), P9-7 and P1-27 (Status Ground) and P9-2 and P1-27 ( Start/
Stop Ground). Repair as necessary. Make sure connector pin sockets are not damaged or corroded
and that they are fully seated and can’t be pulled out. Replace the control board (p. 11-1) if the genset
still does not start.
9. Remove the top housing panel (p. 4-4) and check that both harness connectors labeled B1−BAT
are secure on the starter solenoid terminal, that GND is secure on the chassis ground and that there
is wiring continuity in the harness between connectors P1-10 and B1−BAT and between connectors
P1-27 and GND. Repair as necessary. Make sure connector pin sockets are not damaged or cor-
roded and that they are fully seated and can’t be pulled out. Replace the control board (p. 11-1) if
the genset still does not start.
10. Remove the top housing panel (p. 4-4) and replace broken or missing cables between TB1 and the
engine. Tighten loose connections.

12-2
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

THE STARTER ENGAGES AND DISENGAGES

(Low cranking voltage)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.

THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE

(Marginal battery, battery connections or charging system)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
2. Models HDKCA and HDKCB − The genset starting battery is recharged by the vehicle engine or
separate battery charger. Service as required.
3. Models HDKCC and HDKCD − These models have a feature whereby genset battery charging al-
ternator G1 (p. 9-3) can be disabled, via relay K1 (p. 11-5), by connecting B+ to remote connector
pin P8-D. Service the vehicle engine or separate battery charger if depended upon for recharging
the genset starting battery. If genset battery charging alternator G1 is not disabled, continue with
Step 4.
4. Remove the top housing panel (p. 4-4) and check for wiring continuity in the harness between charg-
ing alternator G1 and starter solenoid terminal B+ (BAT). Repair as necessary.
5. Check for proper operation of relay K1 and replace if necessary (p. 11-5).
6. Check for wiring continuity in the harness between connectors G1-VR and K1-87a. Repair as neces-
sary.
7. Disconnect harness connector P1 from the control board (p. 11-1). Check for wiring continuity in the
harness between connectors P1-24 and K1-30. Repair as necessary. Make sure connector pin sock-
ets are not damaged or corroded and that they are fully seated and can’t be pulled out.
8. Replace battery charging alternator G1 (p. 9-3).

NO AC POWER WHEN GENSET IS RUNNING

(A Circuit Breaker is OFF, tripped or malfunctioning or there are poor AC harness connections)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Reset or turn ON genset circuit breaker CB1.
2. Reset or turn ON any other circuit breaker in the AC power supply system.
3. Check voltage at genset AC output terminal block TB2 when the genset is running. If there is approxi-
mately 120 VAC across TB2-1 and TB2-3 and across TB2-2 and TB2-3, repair or reconnect the wir-
ing between the genset and the main vehicle distribution panel. If there is no voltage, go to Step 4.
4. Check for proper AC harness connections and repair as necessary (p. A-3).
5. Test each circuit breaker and replace if necessary (p. 11-5).

12-3
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

ENGINE OVER TEMPERATURE—CODE NO. 1

(During normal operation engine coolant temperature exceeded 239 F [115 C] for 10 seconds)
Corrective Action:
1. Check engine coolant level, add coolant as necessary and repair any leaks.
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset
and clean out dirt fouling the radiator passages.
3. Run fewer appliances at the same time to keep down engine temperature. (Note that high altitude
and high ambient temperature decrease engine cooling capacity.)
4. Look for loose or broken fan belts and readjust or replace as necessary (p. 8-1).
5. Check for air leaks in the housing as a result of missing or loose housing panels and access covers,
including the access cover for the AC terminals (Figure ).
6. If loose, reconnect wiring harness connector E3-1 to engine coolant temperature sender E3 (p. 9-3).
(The Controller interprets a loose lead touching ground as high temperature.)
7. Replace the coolant thermostat, which might not be fully opening. See Engine Workshop Manual
981-0541.
8. Test temperature sender E3 and replace if necessary (p. 9-3).

LOW OIL PRESSURE—CODE NO. 2

(During normal operation engine oil pressure dropped to less than 14 psi for 3 seconds—switch closed)
Corrective Action:
1. Check engine oil level, add oil as necessary and repair any leaks.
2. Drain the excess oil if the level is above Full on the dipstick. If the level is too high the crankshaft can
whip the oil into foam, which the pump can’t pump.)
3. Test low oil pressure cutoff switch S2 and replace if necessary (p. 9-3).
4. Service the engine. See Engine Workshop Manual 981-0541.

SERVICE CHECK—CODE NO. 3

(A second-level fault occurred)
Corrective Action: Check the second-level fault code by momentarily pressing Stop. The second-lev-
el fault will be one of the following in this table.

12-4
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

OVER CRANK—CODE NO. 4

(First-level fault code—Cranking time exceeded 35 seconds)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-5).If the fuel pump does not operate, check for
loose wiring harness connectors E2-1 and E2-2 and reconnect them to the pump. If they were found
connected, disconnect them and power the pump directly with a 12 volt battery. Replace the fuel
pump if it does not operate. If the pump operates, disconnect P1 from the control board (p. 11-1) and
check for wiring continuity in the harness between connectors P1-24 and E2-1 and for ground conti-
nuity at connector E2-2. Repair as necessary. Make sure connector pin sockets are not damaged
or corroded and that they are fully seated and can’t be pulled out. Replace the control board if the
fuel pump still does not operate.
3. Check the engine air filter and remove any blockage (p. 3-5).
4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
5. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
6. Replace the fuel filter (p. 3-8).
7. Conduct a fuel flow test and service as necessary (p. 5-1).
8. If loose, reconnect wiring harness connector HR-1 to the glow plug bus bar. If it was found connected,
check for B+ on the glow plug bus bar while cranking. If there is B+, remove the glow plug bus bar
and check for electrical continuity between each glow plug terminal and ground. Replace all three
glow plugs if any glow plug is open (p. 9-3). If there is no B+, check for proper operation of glow
plug relay K3 (p. 11-5). If the relay functions properly, check for wiring continuity in the harness be-
tween connectors HR1 and K3-87 and for ground continuity at K3-86. If good, disconnect harness
connector P1 from the control board (p. 11-1) and check for wiring continuity in the harness between
connectors P1-23 and K3-85 and between P1-10 and K3-30. Repair as necessary. Make sure con-
nector pin sockets are not damaged or corroded and that they are fully seated and can’t be pulled
out. Replace the control board if there still is no B+ at the glow plug bus bar during cranking.
9. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-4). (The
engine cannot start if the actuator fails to pull in its spring-loaded plunger.)
10. Service the fuel injectors and injection pump (p. 9-1).
11. Service the internal engine governor mechanism (p. 9-1).
12. Service a worn engine (p. 9-1).

OVER VOLTAGE—CODE NO. 12

(After voltage regulation was enabled Output Voltage jumped to more than 150 VAC
[125% of rated] for 75 milliseconds or to more than 138 VAC [115% of rated] for 3 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF, start the genset and measure output voltage. If output voltage
is normal, the problem is in the circuits external to the genset. If there is no voltage, test for and ser-
vice a grounded or shorted main, field or quadrature windings (p. 10-1) or grounded or shorted volt-
age sense transformer (p. 11-5).
2. Replace the control board (p. 11-1).

12-5
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

UNDER VOLTAGE—CODE NO. 13

(After voltage regulation was enabled Output Voltage fell to less than 108 VAC
[90% of rated] for 5 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF, start the genset and measure output voltage. If output voltage
is normal, the problem is in the circuits external to the genset. If there is no voltage, test for and ser-
vice a grounded or shorted main, field or quadrature windings (p. 10-1) or grounded or shorted volt-
age sense transformer (p. 11-5).
2. Replace the control board (p. 11-1).

OVER FREQUENCY—CODE NO. 14

(After the starter was engaged Frequency jumped to more than 70 Hz
for 40 milliseconds or to more than 66 Hz for 6 seconds)
Corrective Action:
1. Check for a tripped genset circuit breaker, reset it if necessary, and run with fewer connected loads.
(A breaker tripping under load can cause genset frequency to overshoot.)
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can
disrupt frequency.)
3. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-4).
4. Check high-idle speed and readjust if necessary (p. 9-4).
5. Replace the control board (p. 11-1).
6. Service the internal engine governor mechanism according to Engine Workshop Manual 981-0541.

UNDER FREQUENCY—CODE NO. 15

(During normal operation Frequency fell to less than 54 Hz for more than 8 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF and restart the genset. If the genset now runs, run it with fewer
connected loads, especially those with high motor starting loads such as air conditioners.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can dis-
rupt frequency.)
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-5).
4. Replace the fuel filter (p. 3-8).
5. Conduct a fuel flow test and service as necessary (p. 5-1).
6. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-4).
7. Check high-idle speed and readjust if necessary (p. 9-4).
8. Replace the control board (p. 11-1).
9. Service the fuel injectors and injection pump (p. 9-1).
10. Check fuel injection timing (p. 9-1).
11. Service the internal engine governor mechanism (p. 9-1).
12. Service a worn engine (p. 9-1).

12-6
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

ACTUATOR SHORTED OR OPEN—CODE NO. 19

(At startup the Controller sensed an open or shorted governor actuator/harness)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. If loose, reconnect wiring harness connectors E1-1 and E1-2 to the governor actuator. If they were
found connected, disconnect the wiring harness and measure electrical resistance across the actua-
tor leads. Replace the actuator if resistance is not 2.8 to 2.9 ohms.
2. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors P1-28 and E1-1 and for ground continuity at connector E1-2. Re-
pair as necessary. Make sure connector pin sockets are not damaged or corroded and that they are
fully seated and can’t be pulled out. Replace the control board if the fault still occurs.

ACTUATOR OVERLOAD—CODE NO. 22

(Due to connected overload or low engine performance, the Controller maintained the governor actuator
at full-duty cycle—maximum pulse-width-modulated square-wave signal [PWM]—for
60 consecutive seconds)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-5).
4. Replace the fuel filter (p. 3-8).
5. Conduct a fuel flow test and service as necessary (p. 5-1).
6. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-4).
7. Check high-idle speed and readjust if necessary (p. 9-4).
8. Service the fuel injectors and injection pump (p. 9-1).
9. Check fuel injection timing (p. 9-1).
10. Service the internal engine governor mechanism (p. 9-1).
11. Service a worn engine (p. 9-1).

FAULTY ENGINE TEMPERATURE SENDER—CODE NO. 24

(After 10 minutes of normal operation the Controller checked for and sensed
an open temperature sender/harness)
Corrective Action:
1. If loose, reconnect wiring harness connector E3-1 to engine coolant temperature sender E3 (p. 9-3).
2. Test the temperature sender and replace if necessary (p. 9-3).
3. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors P1-21 and E3-1. Repair as necessary. Make sure connector pin
sockets are not damaged or corroded and that they are fully seated and can’t be pulled out. Replace
the control board if the fault still occurs.

12-7
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

VAC SENSE LOST—CODE NO. 27

(The Controller lost VAC sensing during normal voltage regulation when the field was functioning nor-
mally and frequency was at least 40 Hz)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Disconnect harness connector P1 from the control board (p. 11-1) and check for electrical resistance
between pins P1-33 and P1-34, which should be approximately 586 ohms (TX1 secondary winding,
p. 11-5). Go to Step 2 if the secondary circuit of voltage sense transformer TX1 is good. If not, discon-
nect the four harness leads from TX1 and test the transformer. Replace the transformer if either wind-
ing is faulty. If the transformer is good, check wiring continuity in harness leads P1-33—TX1-RED
and P1-34—TX1-GRN. Repair or replace components as necessary. Make sure connector pin sock-
ets are not damaged or corroded and that they are fully seated and can’t be pulled out.
2. Make sure the line circuit breaker (CB1/CB2) is OFF, disconnect the four harness leads from TX1
and test the transformer. Replace the transformer if either winding is faulty. If the transformer is good,
check electrical resistance between harness leads TX1-S1 and TX1-S2, which should be approxi-
mately twice the individual winding resistances in Table 10-1 (T1−T2 + T3−T4). If not, check wiring
continuity in harness leads CB1-LINE—TX1-S1 and CB2-LINE—TX1-S2 and for proper connec-
tions of both sense leads and generator leads to the line terminals on CB1 and CB2. Repair, recon-
nect or replace components as necessary.
3. Replace the control board (p. 11-1).

HIGH BATTERY VOLTAGE—CODE NO. 29

(During startup the Controller sensed that battery system voltage was greater than 19.2 volts for 5 milli-
seconds or greater than 19.2 volts for 1 second will running)
Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.

12-8
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

STARTING FAULT—CODE NO. 32

(The Controller could not detect cranking speed [quadrature zero crossings] for 12 seconds)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
3. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
4. Remove the top housing panel (p. 4-4) and check for wiring continuity in the harness between con-
nectors SW (starter solenoid) and K2-87 (starter pilot relay) and between K2-30 and B+ (BAT) (start-
er solenoid). Repair as necessary.
5. Check for proper operation of starter pilot relay K2 and replace if necessary (p. 11-5).
6. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors J1-12 and K2-85 and for ground continuity at connector K2-86.
Repair as necessary. Make sure connector pin sockets are not damaged or corroded and that they
are fully seated and can’t be pulled out.
7. Service or replace the starter motor assembly (p. 9-3).
8. Replace the control board (p. 11-1).

EE CHECKSUM FAULT—CODE NO. 35

(During startup the genset Controller detected an EE memory error)
Corrective Action: Replace the control board (p. 11-1)

MECHANICAL FAULT—CODE NO. 36

(The Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds, though
not by Controller action)
Corrective Action:
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-5).
3. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
4. Check the engine air filter and remove any blockage (p. 3-5).
5. Replace the fuel filter (p. 3-8).
6. Conduct a fuel flow test and service as necessary (p. 5-1).
7. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-4).
8. Replace the control board (p. 11-1).
9. Service the engine (p. 9-1).

12-9
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

INVALID SET CONFIGURATION FAULT − CODE NO. 37

(If continuous ’Stop’ input is connected to Ground or if MAT sensor input is not Open. Logic is checked
at every Start or Prime attempt.)
Corrective Action:
1. Check for any ’open’ wire connections for continuous Stop and MAT sensor and repair accordingly.

FIELD OVERLOAD—CODE NO. 38

(During normal voltage regulation Field Voltage exceeded 180 VAC for 10 seconds)
Corrective Action:
1. Reduce the number of air conditioners running at the same time, and other appliances that cause
low power factor. (The lower the power factor of a motor or compressor, the more current it draws
per kilowatt. The genset Controller, in turn, must boost field voltage to meet the higher demand for
current imposed by low power factor.)
2. Have the air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause a very low power factor.)
3. Test the generator field and stator windings and service as necessary (p. 10-1).

GENERATOR ROTOR SHORT—CODE NO. 41

(While flashing the field the Controller sensed that the rotor circuit was shorted to ground)
Corrective Action:
1. Disconnect Generator connector J3/P3 and check for a short to ground at P3-7 and at P3-8 (p. 10-1).
Service or replace brushes, slip rings and rotor as necessary.
2. Replace the control board (p. 11-1).

ROM FAULT—CODE NO. 42

(During startup the genset Controller detected a ROM memory error)
Corrective Action: Replace the control board (p. 11-1)

RAM FAULT—CODE NO. 43

(During startup the genset Controller detected a RAM memory error)
Corrective Action: Replace the control board (p. 11-1)

SPEED SENSE LOST—CODE NO. 45

(After start disconnect the Controller lost speed sense [quadrature zero crossings] for 0.25 seconds)
Corrective Action:
1. Disconnect Generator connector J3/P3 and check for open and shorted field (P3-7—P3-8) and
quadrature (P3-3—P3-6) windings (p. 10-1). Service or replace brush block, slip rings, rotor or stator
as necessary.
2. Replace the control board (p. 11-1).

12-10
 TABLE 12-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

LOSS OF FIELD SENSE—CODE NO. 48

(The field sense circuit on the Controller circuit board failed during normal voltage regulation)
Corrective Action: Replace the control board (p. 11-1)

OVERPRIME—CODE NO. 57
(The local or remote control switch was held in the Prime position for more than 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.

12-11
THIS PAGE LEFT INTENTIONALLY BLANK

12-12
13. Bolt Torques

lb-ft N-m
Housing Panel Screws 7-9 10-12
Intake Air Hose Clamp Screws 7-9 10-12
Intake Air Resonator Mounting Screws 6-12 lb-inch 0.7-1.4
Radiator Access Plate Screws 7-9 10-12
Fuel Pump and Fuel Filter Bracket Mounting Screws 7-9 10-12
Fuel Fittings at Pump and Fuel Filter—One Flat passed finger tight. − −
Exhaust Assembly Flange Screws and Nuts 16-20 22-28
Battery Cable Terminal Block Terminal Nuts 6.7-8.3 9-11
Battery Cable Terminal Block Mounting Screws 7-9 10-12
Starter Solenoid Terminal Nuts 4.4-8.7 5.9-11.8
AC Output Terminal Block Terminal Screws 12-14 lb-inch 1.4-1.6
AC Output Terminal Block Mounting Screws 20-22 lb-inch 2.2-2.5
Circuit Breaker Terminal Screws 12-14 lb-inch 1.4-1.6
Circuit Breaker Mounting Screws 12-14 lb-inch 1.4-1.6
Vibration Isolator Mounting Screws 7-9 10-12
Primary Vibration Isolator Center Bolt* 43-53 58-72
Secondary Vibration Isolator Center Bolt* 27-30 37-41
Generator Drive Disc to Flywheel Bolts* 24-32 33-44
Generator Drive Disc to Rotor Bolts* 19-21 25-29
Generator Through Bolt Nuts* 20-25 28-34
Generator to Flywheel Housing Bolts* 39 52
Flywheel Housing Mounting Bolts* 30-40 41-55
Flywheel Mounting Bolts* 65-80 88-108
Starter Mounting Bolts* 18-22 24-30
Engine Mounting Bracket Bolts* 36-43 48-58
Engine Lifting Bracket Bolts* 18-22 24-30
Engine Oil Drain Plug* 32 44
Fan Spacer Bolts* 18-22 24-30
Free-Spinning Fan Coupling (Pulley)* 103-118 137-157
M6 Engine Bolts Except When Otherwise Specified* 5.8-6.9 7.9-9.3
M8 Engine Bolts Except When Otherwise Specified* 13.0-15.2 17.7-20.6
M10 Engine Bolts Except When Otherwise Specified* 28.9-33.3 39.2-45.1
M12 Engine Bolts Except When Otherwise Specified* 46.3-53.5 62.8-72.6
Oil Filter Adapter Mounting Nut 40−50 −
Remote Oil Line Fittings 24−26 −
Remote Oil Filter Elbow — One Full Turn Past Hand Tighten − −
* − Use engine oil as a thread lubricant.

13-1
THIS PAGE LEFT INTENTIONALLY BLANK

13-2
14. Specifications

MODEL: HDKCA HDKCB

GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,500 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 52.1 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.41 lph) 0.11 gph (0.41 lph)
Half-load 0.48 gph (1.82 lph) 0.48 gph (1.82 lph)
Full-load 1.01 gph (3.8 lph) 1.2 gph (4.54 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5
Firing Order 1−3−2
Fuel Nozzle Injection Pressure 1991 psi (13.731 mPa)
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust (cold) 0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 5.9 quart (5.6 liter)
Cooling System Capacity 6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0 F (−17 C)
CCA (Cold Cranking Amps) 650 amps down to −20 F (−29 C)
Battery Recharging Installer must provide for battery charging
WEIGHT: 792 lbs (359 kg) 816 lbs (370 kg)
SIZE (L x W x H): 41.4 x 24.5 x 27 in (105 x 62 x 68.6 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load

14-1
 SPECIFICATIONS
MODEL: HDKCC HDKCD
GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,000 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 50 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.41 lph) 0.11 gph (0.41 lph)
Half-load 0.48 gph (1.82 lph) 0.48 gph (1.82 lph)
Full-load 1.01 gph (3.80 lph) 1.20 gph (4.54 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5
Firing Order 1−3−2
Fuel Nozzle Injection Pressure 1991 psi (13.731 mPa)
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust (cold) 0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 5.9 quart (5.6 liter)
Cooling System Capacity 6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0 F (−17 C)
CCA (Cold Cranking Amps) 650 amps down to −20 F (−29 C)
Maximum Regulated Charging Current 20 amps
WEIGHT: 816 lbs (370 kg) 816 lbs (370 kg)
SIZE (L x W x H): 41.4 x 24.5 x 27 in (105 x 62 x 68.6 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load

14-2
15. Service Checklist
After servicing, inspect and test the installation to nections, welds, gaskets and joints. Also make sure
confirm that the genset will operate as intended. the exhaust pipe is not overheating adjacent materi-
Check each of the areas described below before als or equipment. Do not run the genset until all ex-
putting the genset into service. haust leaks have been repaired.

Housing WARNING Exhaust gas is deadly. The exhaust

Check to see that all housing panels and access system must not leak and must discharge all ex-
covers are in place and secure. haust away from the vehicle. Do not run the gen-
set until the exhaust leaks have been repaired.
Mounting The exhaust tailpipe must be supported by a
hanger near the vehicle perimeter and terminate
Examine all mounting bolts and supporting mem-
at least 1 inch outside the perimeter and at least
bers to verify that the genset is properly mounted.
1 foot from doors and windows.
All fasteners should be tightened securely to pre-
vent them from working loose when subjected to
vibration. Fuel System

Lubrication While the genset is running, inspect the fuel supply

and return lines, filter and fittings for leaks. Check
If the engine oil was drained, refill as required. flexible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything
Cooling System that could cause leakage. Repair all fuel leaks im-
mediately.
If the engine coolant was drained, refill as required.

Wiring WARNING Diesel fuel is combustible. Leaking

fuel could lead to fire and to severe personal in-
Verify that all wiring connections are tight and jury or death. Repair fuel leaks immediately.
installed properly. Check each of these connec-
tions: Control
S Load wires
S Control wires Stop and start the genset several times at the con-
trol panel on the genset and at the remote control
S Ground straps board (if provided) to verify that they work properly.
S Battery cables
Mechanical
Output Check
Apply a full load to make sure the genset can pro- Stop the genset and inspect it for leaking gaskets,
duce rated output. Use a load test panel to apply a loose fasteners, damaged components and inter-
progressively greater load until full load is reached. ference with other equipment. Repair as necessary.
Inspect the generator compartment and verify that
Exhaust System there are no breaks or openings in the vapor-proof
wall that separates the compartment from the ve-
While the genset is running inspect the entire ex- hicle interior. Seal openings as necessary. Make
haust system. Look and listen for leaks at all con- sure that all soundproofing material is in place.

15-1
THIS PAGE LEFT INTENTIONALLY BLANK

15-2
 630-2854

CONTROL SCHEMATIC

A-1
 338-4461

CONTROL WIRING HARNESS

A-2
 AC HARNESS

AC WIRING HARNESS

A-3
THIS PAGE LEFT INTENTIONALLY BLANK
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR , OnanR , the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E 2010 Cummins Power Generation, Inc. All rights reserved.